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.

 

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.

 

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.

 

Folks,

The service manual indicates that A/C Heater Control, Headlamp Switch
and Blower Motor relay are all connected to the same ground point
(G200). A faulty ground connection may explain why these connectors
are melting.

According to the manual, G200 is located "Left Rear of Instrument
Panel". This area was leaking in my Jeep, so I will now go check how
"grounded" that ground really is.

Any other advice also appreciated.

Nick

 

Folks,

The service manual indicates that A/C Heater Control, Headlamp Switch
and Blower Motor relay are all connected to the same ground point
(G200). A faulty ground connection may explain why these connectors
are melting.

According to the manual, G200 is located "Left Rear of Instrument
Panel". This area was leaking in my Jeep, so I will now go check how
"grounded" that ground really is.

Any other advice also appreciated.

Nick

 

Folks,

The service manual indicates that A/C Heater Control, Headlamp Switch
and Blower Motor relay are all connected to the same ground point
(G200). A faulty ground connection may explain why these connectors
are melting.

According to the manual, G200 is located "Left Rear of Instrument
Panel". This area was leaking in my Jeep, so I will now go check how
"grounded" that ground really is.

Any other advice also appreciated.

Nick

 

Folks,

The service manual indicates that A/C Heater Control, Headlamp Switch
and Blower Motor relay are all connected to the same ground point
(G200). A faulty ground connection may explain why these connectors
are melting.

According to the manual, G200 is located "Left Rear of Instrument
Panel". This area was leaking in my Jeep, so I will now go check how
"grounded" that ground really is.

Any other advice also appreciated.

Nick

 

Maybe this recall might help??
------------------------

Recall 99V117000: Instrument Panel Ground Screws Loose

The left side and right side instrument panel wiring ground attachment
screws could loosen over time. If the left side screw loosens, the
instrument panel gauges may not function when the headlamps are turned
on. If the right side screw loosens, the defroster blower motor may
not function.

Dealers will remove the ground screws, drill a new pilot hole adjacent
to the original hole, and the screws will be reinstalled in the new
holes.

Owner notification began May 31, 1999. Owners who take their vehicles
to an authorized dealer on an agreed upon service date and do not
receive the free remedy within a reasonable time should contact
Chrysler at 1-800-992-1997. Also contact the National Highway Traffic
Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT
(1-888-327-4236).
----------------------------

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:
>
> Folks,
>
> The service manual indicates that A/C Heater Control, Headlamp Switch
> and Blower Motor relay are all connected to the same ground point
> (G200). A faulty ground connection may explain why these connectors
> are melting.
>
> According to the manual, G200 is located "Left Rear of Instrument
> Panel". This area was leaking in my Jeep, so I will now go check how
> "grounded" that ground really is.
>
> Any other advice also appreciated.
>
> Nick

 

Maybe this recall might help??
------------------------

Recall 99V117000: Instrument Panel Ground Screws Loose

The left side and right side instrument panel wiring ground attachment
screws could loosen over time. If the left side screw loosens, the
instrument panel gauges may not function when the headlamps are turned
on. If the right side screw loosens, the defroster blower motor may
not function.

Dealers will remove the ground screws, drill a new pilot hole adjacent
to the original hole, and the screws will be reinstalled in the new
holes.

Owner notification began May 31, 1999. Owners who take their vehicles
to an authorized dealer on an agreed upon service date and do not
receive the free remedy within a reasonable time should contact
Chrysler at 1-800-992-1997. Also contact the National Highway Traffic
Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT
(1-888-327-4236).
----------------------------

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:
>
> Folks,
>
> The service manual indicates that A/C Heater Control, Headlamp Switch
> and Blower Motor relay are all connected to the same ground point
> (G200). A faulty ground connection may explain why these connectors
> are melting.
>
> According to the manual, G200 is located "Left Rear of Instrument
> Panel". This area was leaking in my Jeep, so I will now go check how
> "grounded" that ground really is.
>
> Any other advice also appreciated.
>
> Nick

 

Maybe this recall might help??
------------------------

Recall 99V117000: Instrument Panel Ground Screws Loose

The left side and right side instrument panel wiring ground attachment
screws could loosen over time. If the left side screw loosens, the
instrument panel gauges may not function when the headlamps are turned
on. If the right side screw loosens, the defroster blower motor may
not function.

Dealers will remove the ground screws, drill a new pilot hole adjacent
to the original hole, and the screws will be reinstalled in the new
holes.

Owner notification began May 31, 1999. Owners who take their vehicles
to an authorized dealer on an agreed upon service date and do not
receive the free remedy within a reasonable time should contact
Chrysler at 1-800-992-1997. Also contact the National Highway Traffic
Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT
(1-888-327-4236).
----------------------------

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:
>
> Folks,
>
> The service manual indicates that A/C Heater Control, Headlamp Switch
> and Blower Motor relay are all connected to the same ground point
> (G200). A faulty ground connection may explain why these connectors
> are melting.
>
> According to the manual, G200 is located "Left Rear of Instrument
> Panel". This area was leaking in my Jeep, so I will now go check how
> "grounded" that ground really is.
>
> Any other advice also appreciated.
>
> Nick