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Unread 01-25-2015, 01:21 PM   #1
bozsh132
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Need help finding relay/plug part number

Hey guys need some assistance finding the name or part number of this plug/relay. The back of the plug has a number 83159.

I have a 1997 2.5L manual trans.

I recently did a motor swap and having trouble getting it back running so when looking everything over I came across this plug/relay...
I was taking it off to clean corrosion etc. because I noticed how bad the mounting tab itself was (where you would bolt it to the fender).

It is located on the right side(passenger) fender near the battery and under the PDC. (its wires come from PDC)

On a side note
I also broke off the red wire on the harness side when pulling the plug apart, any good ideas to fix this? was thinking of getting the pin out and soldering it back on. (more so worried about the relay/plug part #.

jeep-tj-relay-pic1.jpg   jeep-tj-relay-pic2.jpg   jeep-tj-relay-pic4.jpg   jeep-tj-relay-pic5.jpg  
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Unread 01-25-2015, 01:49 PM   #2
2jhanna
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Most car parts stores will have this. See link below.

http://www.amazon.com/Auto-Truck-Rel.../dp/B007JPPQH6
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Unread 01-25-2015, 02:20 PM   #3
bozsh132
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Quote:
Originally Posted by 2jhanna View Post
Most car parts stores will have this. See link below.

http://www.amazon.com/Auto-Truck-Rel.../dp/B007JPPQH6
thanks for the quick reply...
just a few questions:

do you know if this is the correct application (40AMP) for my 2.5L TJ?

Also, the OEM has a metal tab for mounting, I thought it might be grounded, is that the case?

If so - will the plastic mounting tab on the replacement relay affect anything?


Thanks again
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Unread 01-25-2015, 02:27 PM   #4
JeepnBlake
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It's not grounded through the mounting tab so it's a non issue.
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Unread 01-25-2015, 04:54 PM   #5
bozsh132
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Quote:
Originally Posted by JeepnBlake View Post
It's not grounded through the mounting tab so it's a non issue.
okay gotcha, any idea on the amperage ?
i am unable to find this relay in any of the documentation i've come across
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Unread 01-25-2015, 06:06 PM   #6
DanielW
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Does this help? If this is correct diagram which component is it?
1997_tj_pdc.pdf-adobe-reader.jpg

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Unread 01-25-2015, 06:33 PM   #7
2jhanna
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If any thing, the 40amp is more than you need, but that won't hurt. More is better, in the case of a switch or relay, but not for a fuse.

Just splice in the socket "pigtail harness", doing one wire at a time, from the old socket to the new socket. You can solder/heat shrink, or use crimp on butt connectors
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Unread 01-25-2015, 07:42 PM   #8
bozsh132
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Quote:
Originally Posted by DanielW View Post
Does this help? If this is correct diagram which component is it?
no that only shows the relays inside the PDC, if you look at my 3rd and 4th pictures in the original post it shows the location of the plug (the wires of this plug come out of the PDC and lead to various places such as battery/chassis/block grounds and power.)

Quote:
Originally Posted by 2jhanna View Post
If any thing, the 40amp is more than you need, but that won't hurt. More is better, in the case of a switch or relay, but not for a fuse.

Just splice in the socket "pigtail harness", doing one wire at a time, from the old socket to the new socket. You can solder/heat shrink, or use crimp on butt connectors
Okay wasn't 100% sure if too high amperage was a problem, or if the 40a is sufficient since I can't find the specs of the OEM relay,
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Unread 01-25-2015, 07:57 PM   #9
2jhanna
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Quote:
Originally Posted by bozsh132 View Post



Okay wasn't 100% sure if too high amperage was a problem, or if the 40a is sufficient since I can't find the specs of the OEM relay,
From my experience, I have never seen one of the black"cube style" higher than 40amp.
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Unread 01-26-2015, 04:57 AM   #10
Jonny Jeep
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It's not OEM so you won't find it in the factory service manuals or part lists. Perhaps it's for an aftermarket alarm or immobiliser. If there isn't one fitted that you know of you could reinstate the original wiring.
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Unread 01-26-2015, 09:10 AM   #11
bozsh132
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Quote:
Originally Posted by 2jhanna View Post
From my experience, I have never seen one of the black"cube style" higher than 40amp.
okay thank you.


Quote:
Originally Posted by Jonny Jeep View Post
It's not OEM so you won't find it in the factory service manuals or part lists. Perhaps it's for an aftermarket alarm or immobiliser. If there isn't one fitted that you know of you could reinstate the original wiring.
well that makes sense... maybe I will look into reinstating the original set up once I get it back running correctly, don't want to throw any other possible causes at it right now..
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Unread 01-26-2015, 10:00 AM   #12
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Quote:
Originally Posted by 2jhanna View Post
From my experience, I have never seen one of the black"cube style" higher than 40amp.
They make the basic Bosch pattern relay in both 60 and 70 amp versions with 4 terminals, two of which are larger for the higher current loads.
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Unread 01-26-2015, 04:21 PM   #13
Jonny Jeep
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Can you follow the wires switched by the relay and find the colour of the wire it goes to. If you do that I'll have a look and see what circuit the relay on.

Sent from my B15 using JeepForum
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Unread 01-27-2015, 05:25 PM   #14
bozsh132
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Quote:
Originally Posted by Jonny Jeep View Post
Can you follow the wires switched by the relay and find the colour of the wire it goes to. If you do that I'll have a look and see what circuit the relay on.

Sent from my B15 using JeepForum

this drawing may be a little confusing but i can probably do better this weekend ...

there are 3 wires goin underneath the PDC that aren't visible until I take it all apart,
--theres a smaller gauge wire running to the starter,
--then 2 wires (one black one blue) heading toward this mystery relay/plug...

the yellow wire leads into the firewall, cant tell where it comes out under the dash until the weekend as well (im guessing this yellow wire is why the relay exists)
jeep-tj-relay-pic6drawing.jpg  
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Unread Yesterday, 07:24 AM   #15
DanielW
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Does this help any?
1997_tj_starter_diagram_manualtrans.pdf-adobe-reader.jpg  
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