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Old 07-29-2009, 10:30 AM   #1
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Having AC problems

Hi All,

I need some more help with the AC/venting. Does anyone know what the 3 electrical wires are for on the vacuum/electric mode switch? The ac blows only on the defrost setting which I understand is usually a vacuum problem. I removed the dash to check for a vacuum leak behind the ac/vent switch and one of the 3 wires connected to it became unplugged. I also found 3 wire splices with splice nuts on them. One of the nuts actually fell off. The loose wire that came off came from the center connector. When I reattached it, the ac came back on through the defrost vent. I touched the middle wire a minute later and it was very hot. I'm thinking there may be a short somewhere. I looked at the service manual that I downloaded from Blacktoothgrin (thanks again for inviting me) and found the switch but did not see any info on the electrical wiring to the switch. Any ideas? Could the switch be bad instead of the vacuum? For what it is worth, I thought I could feel suction off one of the vacuum lines though I am not sure which one. Any help would be appreciated. Thanks,

Chris

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Old 07-29-2009, 10:58 AM   #2
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Not sure on your vacuum problem but the hot wire is normal. By normal I mean it is common on a lot of TJ's there is a write up somewhere in the forum for changing out the wires and adding a relay in there to solve that hot wire problem.

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Old 07-29-2009, 02:09 PM   #3
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Hi coyote 94yj,

Thanks for the info. I'll keep searching. I just don't want a melt down/fire. You can see some black marks on the nuts. Look like burn marks to me.
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Old 07-29-2009, 02:10 PM   #4
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Yes, it does get hot and it does need fixing. I'll try and find a link for you.
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Old 07-29-2009, 03:57 PM   #5
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Originally Posted by coyote_94yj View Post
Yes, it does get hot and it does need fixing. I'll try and find a link for you.
coyote 94yj, Thanks. I really appreciate it.

Chris
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Old 07-29-2009, 03:57 PM   #6
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Ohh, NO!!! Your name isn't Chris is it?!?!
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Old 07-29-2009, 04:11 PM   #7
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Ohh, NO!!! Your name isn't Chris is it?!?!
Not if its a bad thing!!!
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Old 07-29-2009, 04:12 PM   #8
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Well, there are too many Chris' in the forum.

And I am one of them.


Chris
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Old 07-29-2009, 04:19 PM   #9
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Here is the thread I was talking about. There is a link to an article by JP Magazine in it on the fix.

http://www.wranglerforum.com/f5/heat...rol-16174.html
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Old 07-29-2009, 04:34 PM   #10
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Here is the thread I was talking about. There is a link to an article by JP Magazine in it on the fix.

http://www.wranglerforum.com/f5/heat...rol-16174.html
Cool Beans. I think that's it!!! I know what I am doing this weekend. Thanks for your help. I really appreciate it and I owe you one.

Chris
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Old 07-29-2009, 04:36 PM   #11
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No Problem. Anything for another Chris.
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Old 07-29-2009, 04:44 PM   #12
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Well, there are too many Chris' in the forum.

And I am one of them.


Chris
Its a good solid name.

Oh, but it gets worse! Are you into wrestling? WWE? Well, apparently I went into a steroid rage and killed my family and my self!!! You would not believe the calls I received from my family and friends to make sure that it was not me on TV.


Chris, thanks again for the help. If you wind up in Charleston, SC let me know and I'll take you out for lunch.

Chris
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Old 07-29-2009, 04:49 PM   #13
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Its a good solid name.

Oh, but it gets worse! Are you into wrestling? WWE? Well, apparently I went into a steroid rage and killed my family and my self!!! You would not believe the calls I received from my family and friends to make sure that it was not me on TV.


Chris, thanks again for the help. If you wind up in Charleston, SC let me know and I'll take you out for lunch.

Chris
Sure thing, but it might be quite a bit before I end up there. I live in England.
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Old 07-29-2009, 04:57 PM   #14
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Sure thing, but it might be quite a bit before I end up there. I live in England.
Well, I just might have to come visit you. Always looking for a good excuss to get back to Europe! But until then, I'll lift a pint of New Castle to you tonight.

Chris
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Old 07-29-2009, 04:59 PM   #15
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Great, thanks. If you ever end up this way, there's a pint of Guinness or what ever you fancy waiting.
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Old 07-29-2009, 05:43 PM   #16
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Sounds like the previous owner already had the "melting" problem and replaced the conector and control box. Just didn't run relays.

Also check the blend door lever..they are also known to break "plastic". Leaving the door closed only sending air to the defroster.
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Old 07-30-2009, 07:55 AM   #17
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Great, thanks. If you ever end up this way, there's a pint of Guinness or what ever you fancy waiting.
I like Guinness. I really love Beamish!! I'll bring my pipes.
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Old 07-30-2009, 08:24 AM   #18
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Sounds like the previous owner already had the "melting" problem and replaced the conector and control box. Just didn't run relays.

Also check the blend door lever..they are also known to break "plastic". Leaving the door closed only sending air to the defroster.
Hi distortedtj,

Thanks. I'll check the blend door lever and see what condition its in. Why do you recommend I don't run the relays? Does that cause other problems? I can clean up the wiring and do a better job of it but my concern now is, what's causing the wiring to heat up and melt/burn?

Oh, BTW, I like your signature and thanks for watching my 6. U.S. Army, retired.
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Old 07-30-2009, 10:33 AM   #19
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Also check the blend door lever..they are also known to break "plastic". Leaving the door closed only sending air to the defroster.
I looked at the service manual and it looks like I will have to remove the heater A/C housing in order to check the blend door lever. Is that correct? If so, I think I just hit my comfort level. I have no experiance with AC repair/ freon recovery or the equipment.
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Old 07-30-2009, 11:23 AM   #20
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Quote:
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Hi distortedtj,

Thanks. I'll check the blend door lever and see what condition its in. Why do you recommend I don't run the relays? Does that cause other problems? I can clean up the wiring and do a better job of it but my concern now is, what's causing the wiring to heat up and melt/burn?

Oh, BTW, I like your signature and thanks for watching my 6. U.S. Army, retired.
No. He was talking about the previous owner. They replaced the wires but didn't run a relay to stop the problem from happening again.
I helped him do his setup. Oh and I gave him the relay and pigtail to do it.

The problem is caused by too much current going through that wire. That's what the relay fixes. That wire just becomes a signal wire for the relay.
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Old 07-30-2009, 01:35 PM   #21
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No. He was talking about the previous owner. They replaced the wires but didn't run a relay to stop the problem from happening again.
I helped him do his setup. Oh and I gave him the relay and pigtail to do it.

The problem is caused by too much current going through that wire. That's what the relay fixes. That wire just becomes a signal wire for the relay.
Thanks Chris, I misread the reply. Relays it is.
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Old 07-30-2009, 08:38 PM   #22
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Yes Run the relays.

The problem with the main power wire is it send straight 12v power to the controls..."TOO MUCH" hence the need or use for the relays.

Chris...I've ripped all that out and set up relays for all the fan speeds as in the write up you posted to the OP awhile back.
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Old 07-31-2009, 08:01 AM   #23
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Yes Run the relays.

The problem with the main power wire is it send straight 12v power to the controls..."TOO MUCH" hence the need or use for the relays.

Chris...I've ripped all that out and set up relays for all the fan speeds as in the write up you posted to the OP awhile back.
Thanks distortedtj,

I'll start pulling things out this weekend and start getting the parts. Will the relays also work on the AC/vent control as well? Thats were I found the melting and hot wire.
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Old 07-31-2009, 09:31 AM   #24
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Oh, what kind of relay switch am I looking for? Is there a certain kind or wattage/amperage I need to look for? Thanks.

Chris
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Old 07-31-2009, 10:55 AM   #25
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Just any old 30 or 40 amp bosch relay will work. Don't go to autozone and ask for a bosch relay. They'll just look at you funny. It's just a standard 12 volt relay like you would find under your hood in the relay box. They look like this...

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Old 07-31-2009, 10:57 AM   #26
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Quote:
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Yes Run the relays.

The problem with the main power wire is it send straight 12v power to the controls..."TOO MUCH" hence the need or use for the relays.

Chris...I've ripped all that out and set up relays for all the fan speeds as in the write up you posted to the OP awhile back.
Ya gotta watch it Tim... Warpiper is named Chris too.
How long did it take you get that done?
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Old 07-31-2009, 11:19 AM   #27
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Thanks Chris,

Thanks for the pictue too. Now I know what I need to get. Lets see what kind of trouble I can get into this weekend!
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Old 07-31-2009, 11:35 AM   #28
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There's a saying in this forum that you should get used to, familiarize yourself with, and never forget.

"Pics or it didn't happen"

Good luck.
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Old 07-31-2009, 12:58 PM   #29
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There's a saying in this forum that you should get used to, familiarize yourself with, and never forget.

"Pics or it didn't happen"

Good luck.
Its a good thing I recharged my camera batteries!
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Old 08-01-2009, 06:09 PM   #30
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Repairs called on account of rain!! (and lack of knowledge)

Which wires go where on the relay switches? I know I have to cut 4 of the wires coming off the switch (insert relay between the cut) that go to the resistor but I don't know which 4 wires. I also need to know what contacts the wires go to on the relay. I know 2 of the contacts will have the cut wire ends from the switch going to it but don't know which ones. Also don't know what goes to the other 2 contacts. I think ground is one but I am not sure where it is coming from.

I have 3 of the 4 relays and only had to go to 3 auto stores to find them. They are Pilot brand, not the Bosch brand. Hopefully that will be ok. They are 12 V, 30A and have 4 connectors. I was in the processes of cleaning up and splicing the 3 wires going to the mode switch when it started to rain. I also sprayed the fan switch with wd40 and took appart the mode switch to clean it up as well. I'll post pictures when I can figure out how to do it.

Thanks,

Chris

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