Hi Folks,

Three electrical connectors have melted in my 2000 Jeep TJ.
Specifically, the A/C Heater Control C1, C2 and Light Dimmer connector.
In addition, the A/C Heater Control switch has also melted (second
time).

Is anyone else experiencing this problem? Is there are solution?
Maybe a grounding issue?

I'm on my second heater control unit and this is getting expensive.


Insight much appreciated. Thanks.
Nick

 

That happened to me in my Cherokee and it has been reported in TJ's
too. It is due to a bad connection on the power plug at the motor
itself in some cases. This causes too much heat in the wires and melts
out the switch.

I would be checking this connection for heat and burned pins.

The TJ's are also blessed with a bunch of defective switches and the
'new' ones are from the same batch..... Folks are saying the new
switches are bad right out of the box....

Mike
86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
88 Cherokee 235 BFG AT's
Canadian Off Road Trips Photos: Non members can still view!
Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
(More Off Road album links at bottom of the view page)

Nick ------ wrote:
>
> Hi Folks,
>
> Three electrical connectors have melted in my 2000 Jeep TJ.
> Specifically, the A/C Heater Control C1, C2 and Light Dimmer connector.
> In addition, the A/C Heater Control switch has also melted (second
> time).
>
> Is anyone else experiencing this problem? Is there are solution?
> Maybe a grounding issue?
>
> I'm on my second heater control unit and this is getting expensive.
>
> Insight much appreciated. Thanks.
> Nick

 

That happened to me in my Cherokee and it has been reported in TJ's
too. It is due to a bad connection on the power plug at the motor
itself in some cases. This causes too much heat in the wires and melts
out the switch.

I would be checking this connection for heat and burned pins.

The TJ's are also blessed with a bunch of defective switches and the
'new' ones are from the same batch..... Folks are saying the new
switches are bad right out of the box....

Mike
86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
88 Cherokee 235 BFG AT's
Canadian Off Road Trips Photos: Non members can still view!
Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
(More Off Road album links at bottom of the view page)

Nick ------ wrote:
>
> Hi Folks,
>
> Three electrical connectors have melted in my 2000 Jeep TJ.
> Specifically, the A/C Heater Control C1, C2 and Light Dimmer connector.
> In addition, the A/C Heater Control switch has also melted (second
> time).
>
> Is anyone else experiencing this problem? Is there are solution?
> Maybe a grounding issue?
>
> I'm on my second heater control unit and this is getting expensive.
>
> Insight much appreciated. Thanks.
> Nick

 

That happened to me in my Cherokee and it has been reported in TJ's
too. It is due to a bad connection on the power plug at the motor
itself in some cases. This causes too much heat in the wires and melts
out the switch.

I would be checking this connection for heat and burned pins.

The TJ's are also blessed with a bunch of defective switches and the
'new' ones are from the same batch..... Folks are saying the new
switches are bad right out of the box....

Mike
86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
88 Cherokee 235 BFG AT's
Canadian Off Road Trips Photos: Non members can still view!
Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
(More Off Road album links at bottom of the view page)

Nick ------ wrote:
>
> Hi Folks,
>
> Three electrical connectors have melted in my 2000 Jeep TJ.
> Specifically, the A/C Heater Control C1, C2 and Light Dimmer connector.
> In addition, the A/C Heater Control switch has also melted (second
> time).
>
> Is anyone else experiencing this problem? Is there are solution?
> Maybe a grounding issue?
>
> I'm on my second heater control unit and this is getting expensive.
>
> Insight much appreciated. Thanks.
> Nick

 

That happened to me in my Cherokee and it has been reported in TJ's
too. It is due to a bad connection on the power plug at the motor
itself in some cases. This causes too much heat in the wires and melts
out the switch.

I would be checking this connection for heat and burned pins.

The TJ's are also blessed with a bunch of defective switches and the
'new' ones are from the same batch..... Folks are saying the new
switches are bad right out of the box....

Mike
86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
88 Cherokee 235 BFG AT's
Canadian Off Road Trips Photos: Non members can still view!
Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
(More Off Road album links at bottom of the view page)

Nick ------ wrote:
>
> Hi Folks,
>
> Three electrical connectors have melted in my 2000 Jeep TJ.
> Specifically, the A/C Heater Control C1, C2 and Light Dimmer connector.
> In addition, the A/C Heater Control switch has also melted (second
> time).
>
> Is anyone else experiencing this problem? Is there are solution?
> Maybe a grounding issue?
>
> I'm on my second heater control unit and this is getting expensive.
>
> Insight much appreciated. Thanks.
> Nick

 

Mike Romain wrote:
> That happened to me in my Cherokee and it has been reported in TJ's
> too. It is due to a bad connection on the power plug at the motor
> itself in some cases. This causes too much heat in the wires and melts
> out the switch.
>
> I would be checking this connection for heat and burned pins.

Thanks. What is the "power plug at the motor"? Do you mean the wiring
harness that connects to the blower motor and supplies power?

Also, any thought how how this would be related to the headlamp /
dimmer connector melting?

Nick

 

Mike Romain wrote:
> That happened to me in my Cherokee and it has been reported in TJ's
> too. It is due to a bad connection on the power plug at the motor
> itself in some cases. This causes too much heat in the wires and melts
> out the switch.
>
> I would be checking this connection for heat and burned pins.

Thanks. What is the "power plug at the motor"? Do you mean the wiring
harness that connects to the blower motor and supplies power?

Also, any thought how how this would be related to the headlamp /
dimmer connector melting?

Nick

 

Mike Romain wrote:
> That happened to me in my Cherokee and it has been reported in TJ's
> too. It is due to a bad connection on the power plug at the motor
> itself in some cases. This causes too much heat in the wires and melts
> out the switch.
>
> I would be checking this connection for heat and burned pins.

Thanks. What is the "power plug at the motor"? Do you mean the wiring
harness that connects to the blower motor and supplies power?

Also, any thought how how this would be related to the headlamp /
dimmer connector melting?

Nick

 

Mike Romain wrote:
> That happened to me in my Cherokee and it has been reported in TJ's
> too. It is due to a bad connection on the power plug at the motor
> itself in some cases. This causes too much heat in the wires and melts
> out the switch.
>
> I would be checking this connection for heat and burned pins.

Thanks. What is the "power plug at the motor"? Do you mean the wiring
harness that connects to the blower motor and supplies power?

Also, any thought how how this would be related to the headlamp /
dimmer connector melting?

Nick

 

Nick ------ wrote:
>
> Mike Romain wrote:
> > That happened to me in my Cherokee and it has been reported in TJ's
> > too. It is due to a bad connection on the power plug at the motor
> > itself in some cases. This causes too much heat in the wires and melts
> > out the switch.
> >
> > I would be checking this connection for heat and burned pins.
>
> Thanks. What is the "power plug at the motor"? Do you mean the wiring
> harness that connects to the blower motor and supplies power?
>
> Also, any thought how how this would be related to the headlamp /
> dimmer connector melting?
>
> Nick

Yes, I mean the first plug on the harness coming out of the motor. The
motor will have a pigtail with a connector on it.

The heat will do the whole circuit and it does strange things to
contacts. Likely the dimmer is on the same fuse link from the power
distribution center. You should check the fuse for signs of melt too.
It can look 'saggy' and will blow easier or die from vibration because
it went crystalline.

I recently had a bulb short internally in the back fixture so both
elements were lit while having to use the one flasher for about a half
hour and it damaged both the brake switch and the signal switch's
contacts from too much heat. They got arced and have taken a while to
start being stable again.