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Old 02-25-2010, 07:12 PM
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A different take on why HVAC connectors melt

I know there has been plenty of discussion here on the melted HVAC switch/connector problem. When I bought my jeep 4 months ago the a/c and fan didn't work. When I looked into it sure enough the mode selector switch connector (3 wires - fan relay, ground, and a/c selector) was melted, disconnected, and taped off. I read the JP magazine article about adding relays. The general consensus seems to be that the fan is drawing too many amps, which causes the overheating. I talked to an independent jeep mechanic here in Orange county and he told me the reason for the overheating is because of a loose connection. This made sense to me since I have a golf cart and if any of the cables connecting the six batteries is loose it will get VERY hot. Chrysler doesn't carry that connector I needed anymore so my only option was to cut it off, pigtail new wires on and put new female spade terminals on. I broke open the melted connector and retrieved the spades. They didn't look like anything off the shelf, so I took them to Carquest and the guy found a perfect match. I soldered them to the pigtails, cleaned up the male tabs on the back of the switch real good and did a test fit of the three new tabs. I gave them a little extra crimp to make sure they slid on nice and tight. Since there was no longer plastic separating them I wrapped each with electrical tape after soldering them to the wire. So far, so good. Everything works great and I've given the fan and heater an extended road test. I guess maybe the moral to the story is to make sure the connections are good and tight. Maybe the connectors aren't designed real well and because jeeps are used offroad they work loose over time. Just my 2 cents.
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Old 02-16-2011, 08:04 PM   #2
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Great write-up.

You would think that this should be common sense but as we know and are sometimes guilty of: common sense does NOT prevail. LOL

Thank You.
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