Re: Fan Switch
 

It would appear from many posts here that the TJ switches are total
crap. You can buy the whole assembly or make the parts guy dig down in
his computer and just order you the switch itself. The switch is about
$15.00.

There was another thread on this and if I remember right, the new ones
out of the box were getting hot almost instantly so it might be a good
idea to have the dash panel open to try them when going shopping.

What happens is a bad connection causes an arc. This is like an arc
weld and is extremely hot. Because it is so localized, it can usually
melt down the switch before heating up the wiring enough to melt the
fuse.

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)

David Owsley wrote:
>
> Has anyone else had troubles with the fan speed selector switch in a TJ
> melting down and not working right? Mine has melted enough that it had
> literally liquified and began to meld with the plug behing it. Is there a
> problem I should be aware of, or did i just get a bad switch from the
> factory? BTW I have a 1999 TJ 4cyl.
>
> Thanks

Re: Fan Switch
 

It would appear from many posts here that the TJ switches are total
crap. You can buy the whole assembly or make the parts guy dig down in
his computer and just order you the switch itself. The switch is about
$15.00.

There was another thread on this and if I remember right, the new ones
out of the box were getting hot almost instantly so it might be a good
idea to have the dash panel open to try them when going shopping.

What happens is a bad connection causes an arc. This is like an arc
weld and is extremely hot. Because it is so localized, it can usually
melt down the switch before heating up the wiring enough to melt the
fuse.

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)

David Owsley wrote:
>
> Has anyone else had troubles with the fan speed selector switch in a TJ
> melting down and not working right? Mine has melted enough that it had
> literally liquified and began to meld with the plug behing it. Is there a
> problem I should be aware of, or did i just get a bad switch from the
> factory? BTW I have a 1999 TJ 4cyl.
>
> Thanks

Re: Fan Switch
 

It would appear from many posts here that the TJ switches are total
crap. You can buy the whole assembly or make the parts guy dig down in
his computer and just order you the switch itself. The switch is about
$15.00.

There was another thread on this and if I remember right, the new ones
out of the box were getting hot almost instantly so it might be a good
idea to have the dash panel open to try them when going shopping.

What happens is a bad connection causes an arc. This is like an arc
weld and is extremely hot. Because it is so localized, it can usually
melt down the switch before heating up the wiring enough to melt the
fuse.

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)

David Owsley wrote:
>
> Has anyone else had troubles with the fan speed selector switch in a TJ
> melting down and not working right? Mine has melted enough that it had
> literally liquified and began to meld with the plug behing it. Is there a
> problem I should be aware of, or did i just get a bad switch from the
> factory? BTW I have a 1999 TJ 4cyl.
>
> Thanks

Re: Fan Switch
 

I don't want to scare you, but I think that your biggest concern is fire
behind the dash. Melted plastic is a sign of heat, with electricity you
get heat from current confronted with resistance. On a blind guess
there's either a design flaw that allows a partial contact in the
switch, an under-sized conductor in the switch, corrosion or poor
mechanical contact between the connector and the switch, poor bonding
between the wires and the connector contacts or a chaffed wire that is
now too narrow to carry the current that the fan draws.

This site says that there were problems with the YJ series fan switches
developing internal resistance and overheating:
<URL:http://www.bc4x4.com/faqs/yj.cfm?cat=12> Dunno if the design flaw
carries over into your TJ, but replacing the switch is obviously in your
future anyway.


David Owsley wrote:
> The fan would run in the 1st, 2nd and halfway between the third and fourth
> position, the contact that melted out of the switch was the contact for the
> high position. I had trouble with this before and was able to rebuild the
> switch, however it melted down again. Just wondering how it got hot enough
> the melt and liquify plastic but not blow a fuse of some kind, this is what
> my biggest concern over this is.
>
>
> "L.W. ("ßill") ------ III" <----------@cox.net> wrote in message
> news:43CC5A99.F3C87CB2@cox.net...
>
>>Hi David,
>> I think maybe one other in this group had that problem, Matt? Seems
>>strange to me as the switch is bypassed in the high position and
>>tempered by a resistor in the lower positions:
>>http://www.----------.com/resistor.htm But a melt down is a melt.
>> God Bless America, Bill O|||||||O
>>mailto:--------------------
>>
>>David Owsley wrote:
>>
>>>Has anyone else had troubles with the fan speed selector switch in a TJ
>>>melting down and not working right? Mine has melted enough that it had
>>>literally liquified and began to meld with the plug behing it. Is there a
>>>problem I should be aware of, or did i just get a bad switch from the
>>>factory? BTW I have a 1999 TJ 4cyl.
>>>
>>>Thanks
>
>
>

Re: Fan Switch
 

I don't want to scare you, but I think that your biggest concern is fire
behind the dash. Melted plastic is a sign of heat, with electricity you
get heat from current confronted with resistance. On a blind guess
there's either a design flaw that allows a partial contact in the
switch, an under-sized conductor in the switch, corrosion or poor
mechanical contact between the connector and the switch, poor bonding
between the wires and the connector contacts or a chaffed wire that is
now too narrow to carry the current that the fan draws.

This site says that there were problems with the YJ series fan switches
developing internal resistance and overheating:
<URL:http://www.bc4x4.com/faqs/yj.cfm?cat=12> Dunno if the design flaw
carries over into your TJ, but replacing the switch is obviously in your
future anyway.


David Owsley wrote:
> The fan would run in the 1st, 2nd and halfway between the third and fourth
> position, the contact that melted out of the switch was the contact for the
> high position. I had trouble with this before and was able to rebuild the
> switch, however it melted down again. Just wondering how it got hot enough
> the melt and liquify plastic but not blow a fuse of some kind, this is what
> my biggest concern over this is.
>
>
> "L.W. ("ßill") ------ III" <----------@cox.net> wrote in message
> news:43CC5A99.F3C87CB2@cox.net...
>
>>Hi David,
>> I think maybe one other in this group had that problem, Matt? Seems
>>strange to me as the switch is bypassed in the high position and
>>tempered by a resistor in the lower positions:
>>http://www.----------.com/resistor.htm But a melt down is a melt.
>> God Bless America, Bill O|||||||O
>>mailto:--------------------
>>
>>David Owsley wrote:
>>
>>>Has anyone else had troubles with the fan speed selector switch in a TJ
>>>melting down and not working right? Mine has melted enough that it had
>>>literally liquified and began to meld with the plug behing it. Is there a
>>>problem I should be aware of, or did i just get a bad switch from the
>>>factory? BTW I have a 1999 TJ 4cyl.
>>>
>>>Thanks
>
>
>

Re: Fan Switch
 

I don't want to scare you, but I think that your biggest concern is fire
behind the dash. Melted plastic is a sign of heat, with electricity you
get heat from current confronted with resistance. On a blind guess
there's either a design flaw that allows a partial contact in the
switch, an under-sized conductor in the switch, corrosion or poor
mechanical contact between the connector and the switch, poor bonding
between the wires and the connector contacts or a chaffed wire that is
now too narrow to carry the current that the fan draws.

This site says that there were problems with the YJ series fan switches
developing internal resistance and overheating:
<URL:http://www.bc4x4.com/faqs/yj.cfm?cat=12> Dunno if the design flaw
carries over into your TJ, but replacing the switch is obviously in your
future anyway.


David Owsley wrote:
> The fan would run in the 1st, 2nd and halfway between the third and fourth
> position, the contact that melted out of the switch was the contact for the
> high position. I had trouble with this before and was able to rebuild the
> switch, however it melted down again. Just wondering how it got hot enough
> the melt and liquify plastic but not blow a fuse of some kind, this is what
> my biggest concern over this is.
>
>
> "L.W. ("ßill") ------ III" <----------@cox.net> wrote in message
> news:43CC5A99.F3C87CB2@cox.net...
>
>>Hi David,
>> I think maybe one other in this group had that problem, Matt? Seems
>>strange to me as the switch is bypassed in the high position and
>>tempered by a resistor in the lower positions:
>>http://www.----------.com/resistor.htm But a melt down is a melt.
>> God Bless America, Bill O|||||||O
>>mailto:--------------------
>>
>>David Owsley wrote:
>>
>>>Has anyone else had troubles with the fan speed selector switch in a TJ
>>>melting down and not working right? Mine has melted enough that it had
>>>literally liquified and began to meld with the plug behing it. Is there a
>>>problem I should be aware of, or did i just get a bad switch from the
>>>factory? BTW I have a 1999 TJ 4cyl.
>>>
>>>Thanks
>
>
>

Re: Fan Switch
 

According to that guy that sells Jeeps and posts here it is really
common, therefore it is a design flaw that 'should' be a recall item.

Fire hazard and no defroster control are both safety issues.

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)

Lee Ayrton wrote:
>
> I don't want to scare you, but I think that your biggest concern is fire
> behind the dash. Melted plastic is a sign of heat, with electricity you
> get heat from current confronted with resistance. On a blind guess
> there's either a design flaw that allows a partial contact in the
> switch, an under-sized conductor in the switch, corrosion or poor
> mechanical contact between the connector and the switch, poor bonding
> between the wires and the connector contacts or a chaffed wire that is
> now too narrow to carry the current that the fan draws.
>
> This site says that there were problems with the YJ series fan switches
> developing internal resistance and overheating:
> <URL:http://www.bc4x4.com/faqs/yj.cfm?cat=12> Dunno if the design flaw
> carries over into your TJ, but replacing the switch is obviously in your
> future anyway.
>
> David Owsley wrote:
> > The fan would run in the 1st, 2nd and halfway between the third and fourth
> > position, the contact that melted out of the switch was the contact for the
> > high position. I had trouble with this before and was able to rebuild the
> > switch, however it melted down again. Just wondering how it got hot enough
> > the melt and liquify plastic but not blow a fuse of some kind, this is what
> > my biggest concern over this is.
> >
> >
> > "L.W. ("ßill") ------ III" <----------@cox.net> wrote in message
> > news:43CC5A99.F3C87CB2@cox.net...
> >
> >>Hi David,
> >> I think maybe one other in this group had that problem, Matt? Seems
> >>strange to me as the switch is bypassed in the high position and
> >>tempered by a resistor in the lower positions:
> >>http://www.----------.com/resistor.htm But a melt down is a melt.
> >> God Bless America, Bill O|||||||O
> >>mailto:--------------------
> >>
> >>David Owsley wrote:
> >>
> >>>Has anyone else had troubles with the fan speed selector switch in a TJ
> >>>melting down and not working right? Mine has melted enough that it had
> >>>literally liquified and began to meld with the plug behing it. Is there a
> >>>problem I should be aware of, or did i just get a bad switch from the
> >>>factory? BTW I have a 1999 TJ 4cyl.
> >>>
> >>>Thanks
> >
> >
> >

Re: Fan Switch
 

According to that guy that sells Jeeps and posts here it is really
common, therefore it is a design flaw that 'should' be a recall item.

Fire hazard and no defroster control are both safety issues.

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)

Lee Ayrton wrote:
>
> I don't want to scare you, but I think that your biggest concern is fire
> behind the dash. Melted plastic is a sign of heat, with electricity you
> get heat from current confronted with resistance. On a blind guess
> there's either a design flaw that allows a partial contact in the
> switch, an under-sized conductor in the switch, corrosion or poor
> mechanical contact between the connector and the switch, poor bonding
> between the wires and the connector contacts or a chaffed wire that is
> now too narrow to carry the current that the fan draws.
>
> This site says that there were problems with the YJ series fan switches
> developing internal resistance and overheating:
> <URL:http://www.bc4x4.com/faqs/yj.cfm?cat=12> Dunno if the design flaw
> carries over into your TJ, but replacing the switch is obviously in your
> future anyway.
>
> David Owsley wrote:
> > The fan would run in the 1st, 2nd and halfway between the third and fourth
> > position, the contact that melted out of the switch was the contact for the
> > high position. I had trouble with this before and was able to rebuild the
> > switch, however it melted down again. Just wondering how it got hot enough
> > the melt and liquify plastic but not blow a fuse of some kind, this is what
> > my biggest concern over this is.
> >
> >
> > "L.W. ("ßill") ------ III" <----------@cox.net> wrote in message
> > news:43CC5A99.F3C87CB2@cox.net...
> >
> >>Hi David,
> >> I think maybe one other in this group had that problem, Matt? Seems
> >>strange to me as the switch is bypassed in the high position and
> >>tempered by a resistor in the lower positions:
> >>http://www.----------.com/resistor.htm But a melt down is a melt.
> >> God Bless America, Bill O|||||||O
> >>mailto:--------------------
> >>
> >>David Owsley wrote:
> >>
> >>>Has anyone else had troubles with the fan speed selector switch in a TJ
> >>>melting down and not working right? Mine has melted enough that it had
> >>>literally liquified and began to meld with the plug behing it. Is there a
> >>>problem I should be aware of, or did i just get a bad switch from the
> >>>factory? BTW I have a 1999 TJ 4cyl.
> >>>
> >>>Thanks
> >
> >
> >

Re: Fan Switch
 

According to that guy that sells Jeeps and posts here it is really
common, therefore it is a design flaw that 'should' be a recall item.

Fire hazard and no defroster control are both safety issues.

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)

Lee Ayrton wrote:
>
> I don't want to scare you, but I think that your biggest concern is fire
> behind the dash. Melted plastic is a sign of heat, with electricity you
> get heat from current confronted with resistance. On a blind guess
> there's either a design flaw that allows a partial contact in the
> switch, an under-sized conductor in the switch, corrosion or poor
> mechanical contact between the connector and the switch, poor bonding
> between the wires and the connector contacts or a chaffed wire that is
> now too narrow to carry the current that the fan draws.
>
> This site says that there were problems with the YJ series fan switches
> developing internal resistance and overheating:
> <URL:http://www.bc4x4.com/faqs/yj.cfm?cat=12> Dunno if the design flaw
> carries over into your TJ, but replacing the switch is obviously in your
> future anyway.
>
> David Owsley wrote:
> > The fan would run in the 1st, 2nd and halfway between the third and fourth
> > position, the contact that melted out of the switch was the contact for the
> > high position. I had trouble with this before and was able to rebuild the
> > switch, however it melted down again. Just wondering how it got hot enough
> > the melt and liquify plastic but not blow a fuse of some kind, this is what
> > my biggest concern over this is.
> >
> >
> > "L.W. ("ßill") ------ III" <----------@cox.net> wrote in message
> > news:43CC5A99.F3C87CB2@cox.net...
> >
> >>Hi David,
> >> I think maybe one other in this group had that problem, Matt? Seems
> >>strange to me as the switch is bypassed in the high position and
> >>tempered by a resistor in the lower positions:
> >>http://www.----------.com/resistor.htm But a melt down is a melt.
> >> God Bless America, Bill O|||||||O
> >>mailto:--------------------
> >>
> >>David Owsley wrote:
> >>
> >>>Has anyone else had troubles with the fan speed selector switch in a TJ
> >>>melting down and not working right? Mine has melted enough that it had
> >>>literally liquified and began to meld with the plug behing it. Is there a
> >>>problem I should be aware of, or did i just get a bad switch from the
> >>>factory? BTW I have a 1999 TJ 4cyl.
> >>>
> >>>Thanks
> >
> >
> >

Re: Fan Switch
 

On Tue, 17 Jan 2006 09:26:58 -0500, Mike Romain <romainm@sympatico.ca>
wrote:

>It would appear from many posts here that the TJ switches are total
>crap. You can buy the whole assembly or make the parts guy dig down in
>his computer and just order you the switch itself. The switch is about
>$15.00.
>
>There was another thread on this and if I remember right, the new ones
>out of the box were getting hot almost instantly so it might be a good
>idea to have the dash panel open to try them when going shopping.
>

I found out you could just buy the switch and not the whole assembly,
I've replaced 3 so far. I quit having the problem when I quit running
the fan on hi, just going to the 3rd setting. I'm guessing the fan
motor draws too much current on hi and needs to be replaced, I just
haven't done that yet. I also had to replace some melted wires.

Joe Carroll

2K-TJ

There are some simple truths...And the dogs know what they are."
Joseph Duemer