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Old 11-16-2009, 10:57 PM   #1
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Blowing Resistors

The risistor for the blower control keeps burning out in my 97 tj. I picked up a used one but it didn't last long. I wasn't sure if it quit because it was used or if I had something else wrong so I bought a new one. It burned out right away. I had the blower out and it seems to runs great when connected direct to the battery but I have nothing really to compare it to. Does this sound more like a wiring issue or a dying motor that's pulling too much current to run? Anyone had this problem before?

Thanks

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Old 11-17-2009, 07:22 AM   #2
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I am having a similar issue and can't figure it out. What resistor are you blowing? I replaced the blower, checked what I thought was all the fuses and resistors and have a switch on order. Reason I am leaning towards the switch is that I can stick two mini screw drivers in the switch terminals to bypass the actual switch and the blower willb turn on.

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Old 11-18-2009, 03:44 PM   #3
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Jp90Talon, don't know what year your jeep is but on mine the blower motor resistor pack controls the first 3 motor speeds of the blower motor. 4th speed powers a relay which provides direct power straight through bypassing the resister and (according to the wiring diagram) is powered off a different breaker. It's located on the passenger side screwed into the HVAC housing directly aft of the blower motor.
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Old 11-18-2009, 04:39 PM   #4
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Oh, what is this? I was expecting electronics porn. The thread title is very misleading.

I'm just kidding. There is a write up around here somewhere that has a fix for your problem. It involves installing relays inline between your controller and the rest of the system. That way the relay carries the load and not the resistor pack. I'll do some looking and see if I can find it.
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Old 11-18-2009, 05:13 PM   #5
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Well Im pretty sure I found part of my issue. I went to replace the entire heater/AC control panel today and found that the furthest plug on the right behind the knobs for some reason melted. Not sure just yet what its for or what caused it but I have a funny feeling it may be the reason its not working. Anyone know what the furthest plug on the right is for with the two black wires and one green?
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Old 11-18-2009, 05:18 PM   #6
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There is too much current going through that circuit or Jeep didn't design that circuit properly. Resistor packs go bad, wires melt. It is a common problem.

I finally found the write-up I mentioned earlier.
Jeep Fire Prevention - Jp Magazine
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Old 11-18-2009, 05:29 PM   #7
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Quote:
Originally Posted by coyote_94yj View Post
There is too much current going through that circuit or Jeep didn't design that circuit properly. Resistor packs go bad, wires melt. It is a common problem.

I finally found the write-up I mentioned earlier.
Jeep Fire Prevention - Jp Magazine
You are now my hero! This is the exact same plug I was talking about! I know know what I need to do.

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Old 11-18-2009, 09:34 PM   #8
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I got tired of messing with mine so I ran a relay with a switch from the battery to the blower. Works perfect but only one speed. One day I wi get around to putting a resister pack that can actually take the load but the only time I run the fan is in the winter so I just control the temp with the temp knob and drown out the noise with 1500w of stereo.
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Old 11-20-2009, 01:48 AM   #9
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Quote:
Originally Posted by Jp90Talon View Post
You are now my hero! This is the exact same plug I was talking about! I know know what I need to do.

Glad I could help.
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Old 11-20-2009, 11:57 PM   #10
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Can anyone give me a better description of how to wire the relays shown in the JP article? JP's description make no sense to me.

Quote:
Wire to blower motor switch (one side of cut wire)Switched, fused battery positiveWire to resistor block (other side of cut wire)To groundThis is the wiring with terminal numbers for the relays we put in.
This connects only two of the terminals of the relay. I'm no electrical genius but don't you need to connect at least four of the terminals for a relay to be of any use?
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Old 11-22-2009, 02:40 PM   #11
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I have a wiring diagram for those relays around here somewhere. I'll look for it and post it up when I find it.
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Old 11-22-2009, 10:27 PM   #12
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I'm resisting!!
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"I'd rather die while I'm living than live while I'm dead"
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Old 11-23-2009, 01:45 AM   #13
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Found it. I drew this up a while ago for my dad for his electric radiator fan but it is the same basic principle and wiring. Even the labels fit.

Hope this helps. You're probably going to need a schematic for you jeep to determine which wires are which in there. When you put in the new fan switch you could install one each of these for each fan speed setting.



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