A/C-Heater Control Vacuum Switch Melting - Jeep Wrangler Forum

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Old 02-03-2011, 10:36 PM   #1
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A/C-Heater Control Vacuum Switch Melting

I have a 2000 TJ and, well, one cold day my blower motor decided to quit on me. After some troubleshooting I narrowed it down to my vacuum switch on the A/C heater controller (wasnt getting a good ground going through that switch); turned out the plug had melted to the switch (which explains the burning I smelled intermittently when I had the heater on). Long story short, I replace the switch and everything works great, but Im concerned about the condition of the connector. It seems to make all the connections fine now, but some of the casing had melted away around middle terminal. Im not sure if this is going to last very long. Does anyone know where I can get a replacement connector or wire harness? I found the vacuum harness listed on Jeep4x4center.com, but it looks like that may just be the vacuum harness, not the electrical harness. Id appreciate any assistance anyone can provide.
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Old 02-03-2011, 11:12 PM   #2
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I was told (by 2 different dealers) that the connector is discontinued. I cut my melted connector off, broke it open and brought one of the female ends to Carquest and they had exact matches. I spliced them onto the cut wires and made sure they slid onto the three male tabs on the back of the switch nice and tight. Then I wrapped each with electrical tape since they were no longer separated with plastic. A jeep mechanic told me they melt because of a loose connection, so make sure everything is nice and tight.

. . . . picking the lines with my twenty-nines . . . .

'99 sport 4.0 5 speed, top-of-the-line floormats
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Old 02-04-2011, 01:40 PM   #3
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Thanks a bunch. That doesn't sound too bad. I appreciate your info! I'll probably do that here in the near future. I'm not too comfortable with leaving it the.way it is for too long.
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Old 02-04-2011, 03:38 PM   #4

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If its the black harness with 3 wires in it, I looked it up and it shows there are 53 in the nation mopar warehouses,. any dealer should be able to order it.

68080536AAThat will get you a new connector along with wire leads to splice into your existing harness.

If you ever need to look up to see if there is an OEM harness repair You can goto this website and put in your year and make then see the connectors.

Mopar Connectors
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Old 02-05-2011, 10:09 AM   #5
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Thanks! I'll add that link to my favorites. Thanks for the info; part number and everything!
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