I have searched and searched the forum but still cannot find a solution to my issue.
Installed a hardtop wiring harness on 2002 wrangler x. Everything works fine except the defroster stays on constantly. When I press the button I hear nothing so not sure if its a relay problem or wiring issue. I have checked my install over and over but I must be overlooking something.
So you are saying that when you turn the key on it comes on & stays on until you turn the key off? Switch does nothing. If so then the relay (in the PDC) would click with the key not the switch.(?) 34-35 just connects the LB/WT wire to the harness which you have to do. Just make sure it is to the same LB/WT wire there. Position 2 I think. Then 43 has to be done to get the cluster timer into the circuit. All of this is to ground the relay coil to turn the defroster on (& start the timer). The defroster will stay on when the key is on if the LB/WT wire gets grounded somewhere before the cluster. That sounds like what you have. It should only get grounded by closing the switch.
Ok is this correct? This is the line from harness connected to 10 way adaptor. Or is it supposed to be line from harness to wire that was connected to 10 way adaptor. With this setup I get no power light when I turn jeep on vs before when it was on all the time. I'm confused about step 43 you mentioned, my instruction just say secure overlay harness
Your instructions are a little different from mine. I have 2 sets one from my '05 HT dated 4-5-2004 & one I found which I thought was for all the earlier kits. It covers 97, 98 & 99 & has a supplement page that has a few corrections for "1999/and later year..." I can see on your posting that that page is different than the one I have but I can see that it says the blue/white wire goes on the gray side of the connector. I think I see on your last post you have it on the black side. I think it was correct before. Just that somewhere that blue/white wire is getting grounded & closing the relay. It seems like it would be the blue/white wire from the relay back to that 10 way connector. Since you have it open there, test it with a meter to see if it is grounded after removing the relay. That wire should not get grounded until you close the switch (when everything is connected & operating properly).
What I was referring to by step 43 is the part where you connect the 2 wires (blue/white & blue/green) into the connector to the cluster.
I forgot to ask if you have the wires to the cluster connected. If so, after changing the blue/white wire to the gray side of the connector, unplug the cluster connector & see if that stops the heater from coming on. It may be that it is grounding inside the cluster & causing all your trouble. One other guy had a bad timer. His was always open if I recall. He had to bypass the cluster By connecting the blue/white & the blue/green wires there & adding a timer relay to control the circuit. Anything can happen.
I will check a few thinks you noted. I see what you mean about black vs gray side of connector. Problem is on 02 there is no blue white on gray side. I can find instructions up to 01 and 03+, but no 2002.
Sorry for the late reply, I’ve been on the road all day. As to the blue/white wire, you say the gray side has no wire in that spot, how was it connected when it was staying on all the time?
It seems like it should work as you have it as long as you also have the wires connected to the cluster timer. If they are connected & it is not working I would try temporarily jumping (connecting) those 2 wires & see if that works. What you need is for the blue/white wire to go from the relay to the switch.
Since the switch works by grounding the circuit, what you can try is to ground the blue/white wire there at the gray connector. That should close the relay & heat the glass. Of course the switched is not in the circuit at that point so the indicator will not light.
As to the instructions for the various yrs, they may be different but all the yrs have the same circuit. It is just where the blue/white wire is in the jeep (which connector) & how the non-HT jeeps are wired from the factory.
I had the bl/wt correct originally. The uploaded picture is INCORRECT. Once I disconnected the 16 way connector from the I/p and reconnected, it worked correctly. Not mechanical but I guess this closed the circuit? No matter what it works now
Also for other 2002 owners, you splice the orange wire to the orange wire behind the hot/cold dial, NOT the tan as most instructions say.