Jeep HVAC Hack Job, Thanks PO! - Jeep Wrangler Forum
Jeep Wrangler Forum

Go Back   Jeep Wrangler Forum > TJ Jeep Wrangler Forum > TJ Tech Forum

Join Wrangler Forum Today


Reply
 
Thread Tools

Please support our sponsors and let them know you heard about them on WranglerForum.com
Old 06-11-2010, 12:01 AM   #1
Jeeper
 
burton160w's Avatar
 
Join Date: Oct 2009
Location: Underneath my TJ
Posts: 1,615
Jeep HVAC Hack Job, Thanks PO!

My blower has only been working on the defroster and has only been working on high, no low nothing else. It's high defrost or nothing. Blows hot. Blows cold. Decided to take a look tonight and I found this gracious hack job. Solder everywhere, no taping or heat-shrink.

Anyone wanna tell me where the wires go to? I've got the FSM and will take a look in there, but with the HVAC removed, I'm trying to figure out what I'm going to have to fix and where to start. There are four wires going to the vacuum controls, with two going to the center (one a thicker gauge).



__________________
It's got a Willy's body, a Chevy engine, Ford axles, GM transmission, and Dodge steering components... it must be a Wrangler.
burton160w is offline   Quote Quick Reply
Old 06-11-2010, 12:25 AM   #2
Nerf gun assassin

WF Supporting Member
::WF Administrator::
 
distortedtj's Avatar
 
Join Date: May 2005
Location: yep right there.
Posts: 21,230
Send a message via Yahoo to distortedtj
Well that is the common melting issue on early TJ hvac contols. the wires are in the correct placement on the connections in your picture. What happens is the 3 pin connector melts...fix....cut it off and use spades to slide over the pins, and wire in relays to prevent further melting issues. You can also use a factory connector but you have to find a donor vehicle to cut it out of. Other wise you have to buy a complete harness from jeep.

Only thing not in place there is the yellow wire. Where does it go//connected on the other end???


Defrost ONLY...is a vacuum leak. The defrost setting is the default for any leak in the system.

distortedtj is offline   Quote Quick Reply
Old 06-11-2010, 12:30 AM   #3
Nerf gun assassin

WF Supporting Member
::WF Administrator::
 
distortedtj's Avatar
 
Join Date: May 2005
Location: yep right there.
Posts: 21,230
Send a message via Yahoo to distortedtj
To correct the issue read over this thread....

http://www.wranglerforum.com/f5/heat...rol-16174.html

Post #10 has a link to the relay fix for the melting issue.

If you have any other questions let us know bud.
distortedtj is offline   Quote Quick Reply
Old 06-11-2010, 01:03 AM   #4
Jeeper
 
burton160w's Avatar
 
Join Date: Oct 2009
Location: Underneath my TJ
Posts: 1,615
Quote:
Originally Posted by distortedtj View Post
To correct the issue read over this thread....

http://www.wranglerforum.com/f5/heat...rol-16174.html

Post #10 has a link to the relay fix for the melting issue.

If you have any other questions let us know bud.
Yea, you free tomorrow or Saturday? I've got cold beer and pizza could definitely be ordered thanks for the quick help. There's a few junker Wranglers in my area I could probably pull a control from to fix the melting problem.

The yellow vacuum line that fell off I reattached to the right space, and it sounds like theres no problem with the flaps turning for the position. It's just there is now NO blowing air at all. No defrost nothing.

The yellow wire is going from the middle prong to the plug down underneath the glove box. I attached some pictures. You can see the yellow wire is wrapped up with a red wire.


__________________
It's got a Willy's body, a Chevy engine, Ford axles, GM transmission, and Dodge steering components... it must be a Wrangler.
burton160w is offline   Quote Quick Reply
Old 06-11-2010, 01:15 AM   #5
Jeeper
 
legman68's Avatar
 
Join Date: Apr 2010
Location: NoCal
Posts: 369
I just went through this too. If the three low speeds aren't working, ck the speed control switch, mine was fried there. Once Distorted gave me the lay-out of those wires, fixed. PM me if you want that diagram, very simple. Or could be that resistor in the above pic. Good luck
__________________
"Are you a pothead Focker?"
legman68 is offline   Quote Quick Reply
Old 06-11-2010, 01:22 AM   #6
Jeeper
 
burton160w's Avatar
 
Join Date: Oct 2009
Location: Underneath my TJ
Posts: 1,615
Quote:
Originally Posted by legman68 View Post
I just went through this too. If the three low speeds aren't working, ck the speed control switch, mine was fried there. Once Distorted gave me the lay-out of those wires, fixed. PM me if you want that diagram, very simple. Or could be that resistor in the above pic. Good luck
Hey I PM'd ya, I'll take it. My speed control seems to be fine, and right now, nothing is working, including my defroster. No blowing whatsoever. and thanks for saying where my blower resistor was, I was JUST about to ask where is the blower resistor to see if that's it! hahaha perfect timing.

As a side question, what is this to? Looks like a light plug, but it's coming off right in the back of the shifter and grouped together with those wires.

Edit: I just pulled my blower resistor and it's full of crud. Dust, leaves, and junk is all stuck in it and I'm thinking that may shorted it somewhere? Any thoughts? It's rusted and grimey looking.

__________________
It's got a Willy's body, a Chevy engine, Ford axles, GM transmission, and Dodge steering components... it must be a Wrangler.
burton160w is offline   Quote Quick Reply
Old 06-11-2010, 10:04 AM   #7
Jeeper
 
mrcarcrazy's Avatar
 
Join Date: Jul 2009
Location: Midland/Odessa, TX
Posts: 3,385
If its rusted I'd replace it. Looks like you need to get all that "redone" wiring out, and re-do it...properly.

Electrical gremlins suck to track down, Best of luck on this one. hopefully there's someone on here local to you that can help. I have no luck explaining my thoughts when trying to do electrical work via internet.
__________________
I need another Jeep...
mrcarcrazy is offline   Quote Quick Reply
Old 06-11-2010, 01:46 PM   #8
Jeeper
 
burton160w's Avatar
 
Join Date: Oct 2009
Location: Underneath my TJ
Posts: 1,615
The only thing is, resistors are $40 to replace, no thanks if thats not the problem. Any way to test the blower resistor?
__________________
It's got a Willy's body, a Chevy engine, Ford axles, GM transmission, and Dodge steering components... it must be a Wrangler.
burton160w is offline   Quote Quick Reply
Old 06-11-2010, 05:03 PM   #9
Jeeper
 
pokey's Avatar
 
Join Date: Feb 2010
Location: backroads of the Mojave
Posts: 1,106
There should be 3 wires going to back of that climate control switch. The two thicker (12 gauge I think) are ground and fan relay, the 18 guage green one is to the a/c control. Mine was hacked when I bought it also. You can't get that female connector anymore so like distorted said use spades.

And I had a jeep mechanic tell me those melt because of a loose connection, not too much current draw from the fan.
__________________
__________________________________________
. . . . picking the lines with my twenty-nines . . . .
__________________________________________

'99 sport 4.0 5 speed, top-of-the-line floormats
pokey is offline   Quote Quick Reply
Old 06-11-2010, 05:46 PM   #10
Jeeper
 
legman68's Avatar
 
Join Date: Apr 2010
Location: NoCal
Posts: 369
Like I said, I'm no pro, but we tested the voltage at the motor, if the resistor is working, you should get different voltages at each speed. If you don't, may be it. May not, that's the rub! I'm not sure pokey, that connection at the speed control is pretty positive, I don't see how it could get loose. If you've run the blower with the control in your hand, you feel the buzz from that current, IMO.
__________________
"Are you a pothead Focker?"
legman68 is offline   Quote Quick Reply
Old 06-11-2010, 05:49 PM   #11
Jeeper
 
legman68's Avatar
 
Join Date: Apr 2010
Location: NoCal
Posts: 369
BTW, burton, that looks like a stereo power distribution block. Used to use those back in the day for multiple amps. Usually a larger gauge wire in, multiple smaller out.
__________________
"Are you a pothead Focker?"
legman68 is offline   Quote Quick Reply
Old 06-11-2010, 06:05 PM   #12
Jeeper
 
pokey's Avatar
 
Join Date: Feb 2010
Location: backroads of the Mojave
Posts: 1,106
Those three pins on the climate switch in the first pic should be side by side, all in a row. It looks like someone did a major hack job trying to piece it back together. I wouldn't trust it.

When I bought my jeep nothing worked so when I got back there I found that 3 wire connector all melted, unplugged and taped off. I had no luck at the dealer getting that connector, it's discontinued. I took pliers to the melted connector and retrieved the female spades. They weren't your usual looking off the shelf connectors so I brought them to carquest and they had an exact match. I used solder and shrink tube and gave them a little extra crimp to make sure they slid on tight.

And the loose connection thing made sense to me because I have a golf cart with six batteries and if a a cable is loose it gets REAL hot. Maybe jeeps shake the hell out of those connections and they loosen ?? But I'm no mechanic. And if I didn't have the FSM the above fix would have been a nightmare.
__________________
__________________________________________
. . . . picking the lines with my twenty-nines . . . .
__________________________________________

'99 sport 4.0 5 speed, top-of-the-line floormats
pokey is offline   Quote Quick Reply
Old 06-11-2010, 10:17 PM   #13
Jeeper
 
burton160w's Avatar
 
Join Date: Oct 2009
Location: Underneath my TJ
Posts: 1,615
Quote:
Originally Posted by legman68 View Post
BTW, burton, that looks like a stereo power distribution block. Used to use those back in the day for multiple amps. Usually a larger gauge wire in, multiple smaller out.
Oh, not the power distribution block, the small plug that I'm holding And how do you go about testing the voltages, like step by step I'm not competent with a voltmeter - have one, can't use it.

Side Story: Today I was mudding and my Jeep kept shutting off. I was by myself (I was heading to work and the trails conveniently are a shortcut to work ) and I'm oh crap. Opened up the hood, and my battery fused itself to the body because it wasn't tightened down enough.

__________________
It's got a Willy's body, a Chevy engine, Ford axles, GM transmission, and Dodge steering components... it must be a Wrangler.
burton160w is offline   Quote Quick Reply
Old 06-11-2010, 10:50 PM   #14
Jeeper
 
pokey's Avatar
 
Join Date: Feb 2010
Location: backroads of the Mojave
Posts: 1,106
^ I'm going to go cinch my cables down right now. Ouch !
__________________
__________________________________________
. . . . picking the lines with my twenty-nines . . . .
__________________________________________

'99 sport 4.0 5 speed, top-of-the-line floormats
pokey is offline   Quote Quick Reply
Old 06-14-2010, 11:18 AM   #15
Jeeper
 
burton160w's Avatar
 
Join Date: Oct 2009
Location: Underneath my TJ
Posts: 1,615
Yea that was my fault for not tightening the bracket holding the battery down all of the way. Oddly enough I had the correct wrench for it in the back to tighten and reposition the bracket.
__________________
It's got a Willy's body, a Chevy engine, Ford axles, GM transmission, and Dodge steering components... it must be a Wrangler.
burton160w is offline   Quote Quick Reply
Old 08-18-2010, 03:41 PM   #16
Newb
 
Join Date: Aug 2010
Location: Austin, Texas
Posts: 5
Melted wires on HVAC control

On my '99 TJ I have the same problem, the wires are melted on the 3 prong plug, (actually the plug is melted). I can wiggle this around and the blower will come on. I tried to follow the link on how to install a relay and some spade lugs, but all I get is a blank screen.....I even went to jpmagazine nd tried to go to the tech forum but got the same result. Can anyone give me a brief description on how to install a relay in this circuit? I'm going to just try the spade lugs first, but it's 103 here in Austin and too hot outside to do anything but play in the sprinkler. Will do the spade lug thing tonight after it cools of to 90....
MrChili is offline   Quote Quick Reply
Old 08-23-2010, 09:18 AM   #17
Jeeper
 
up2nogood's Avatar
 
Join Date: Jan 2010
Location: Marion, N.C.
Posts: 54
On my Jeep, everything worked ok for a while, then my blower wouldn't work on any setting except high. Turns out, there is a thermal fuse on the board that mounts into the blower cavity in the passenger side footwell. My buddy replaced the fuse and everything works fine now.
__________________
If Mother-in-laws were flowers.......I'd spray mine with ROUND-UP!
up2nogood is offline   Quote Quick Reply
Old 08-23-2010, 09:53 PM   #18
Nerf gun assassin

WF Supporting Member
::WF Administrator::
 
distortedtj's Avatar
 
Join Date: May 2005
Location: yep right there.
Posts: 21,230
Send a message via Yahoo to distortedtj
^^^ Rheostat relay.
distortedtj is offline   Quote Quick Reply
Old 08-24-2010, 12:28 AM   #19
Newb
 
Join Date: Aug 2010
Location: Austin, Texas
Posts: 5
Rheostat relay? Where is it located? I replaced the OEM connector with spade lugs but the connection still gets so hot you can feel it in the knob. Everything works, just gets hot. If there is a way to put a relay in the circuit, it would solve the problem. Can anyone give me a hint as to how to install one?
Thanks,
MrChili
MrChili is offline   Quote Quick Reply
Old 08-24-2010, 12:58 AM   #20
Jeeper
 
meyers's Avatar
 
Join Date: Apr 2009
Location: Dover, New Hampshire
Posts: 738
Quote:
Originally Posted by burton160w View Post
The only thing is, resistors are $40 to replace, no thanks if thats not the problem. Any way to test the blower resistor?
I would check around,$40 seems high. I got one right at my dealer for like $14 or $19.95 takes like 5 minutes to change

meyers is offline   Quote Quick Reply
Reply

Quick Reply
Message:
Options

Register Now

In order to be able to post messages on the Jeep Wrangler Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
If you do not want to register, fill this field only and the name will be used as user name for your post.
Password
Please enter a password for your user account. Note that passwords are case-sensitive.
Password:
Confirm Password:
Email Address
Please enter a valid email address for yourself.
Email Address:

Log-in

Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off


Similar Threads
Thread Thread Starter Forum Replies Last Post
Jeep towing problem IBHIPRU General Jeep Discussion 6 05-29-2012 06:33 PM
Biggest Jeep Freek Contest!!!! txoutdoorx4 Classifieds Archive 6 02-21-2011 10:48 AM
History of the Jeep. George T. General Jeep Discussion 8 02-04-2009 01:03 AM
Had the best ride in my Jeep so far.... hedonist Off-Topic 8 01-08-2008 10:06 AM



» Network Links
»Jeep Parts
» Featured Product

All times are GMT -5. The time now is 10:51 PM.



Jeep®, Wrangler, Liberty, Wagoneer, Cherokee, and Grand Cherokee are copyrighted and trademarked to Chrysler Motors LLC.
Wranglerforum.com is not in any way associated with the Chrysler Motors LLC