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Old 11-30-2012, 11:58 PM   #1
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Trouble with heater

I have a 2000 tj 5 speed manual with the 4.0. The heater kicks on and off. Sometimes not coming on at all then one day pops on then shuts off. I've replaced the blower resistor and switch itself. The fuses are all good. Still having trouble. Any ideas what to check/replace next?

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Old 12-01-2012, 12:01 AM   #2
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Have you checked for any chafed or loose wiring?

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Old 12-01-2012, 12:08 AM   #3
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That's a good question. No but that will be my next step. I'm actually kicking myself now haha. I've had the dash apart and never thought to check. I'll be doing that tomorrow. Anyone know how the wiring routes behind the dash? I have a hanes manual but it just gives a basic wiring diagram.
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Old 12-01-2012, 12:21 AM   #4
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Lol I have no clue what the routing is but one of my old full size Chebbies had a similar problem and I tracked it down to an exposed and corroded wire going to the blower motor. I'm also currently chasing gremlins out of my TJ's sound system.
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Old 12-01-2012, 12:41 AM   #5
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Yea wiring can be a PITA. I'll just have to do some wire chasing. I just hate trying to track wires through the harness bundle. I feel like I'll miss a connection somewhere. I'm no good at audio systems. I just take it to an audio shop.
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Old 12-01-2012, 12:55 AM   #6
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A few weeks ago I was tasked with troubleshooting and replacing a particular triaxial cable on an F/A-18... I'm pretty sure my blood pressure spiked and took YEARS off my life. Two things I hate: aircraft wiring and automotive interior plastic.
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Old 12-01-2012, 01:02 AM   #7
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Haha I can believe that. I had a couple buddies in aircraft mechanics usually working on harriers or prowlers. They used to tell me the stories. It's a serious task fixing any aircraft. I don't mind electrical to much. Just the harness bundle limits the ability to follow the wire unless you tear it apart. I worked on hmmwvs and 7-tons. That wiring sucked. It was all mostly the same color, black. You had to look for the tiny tag on the wire giving you a number to tell what it was.
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Old 12-01-2012, 01:16 AM   #8
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Prowlers fit somewhere between wiring and car plastic. I never touched one I just hate how they rattle the teeth out of your head. Our Prowler squadron on the Stennis LOVED their high power turns.

Ahh yes. That tiny little ref des on the bundles that tends to fade to a mere watermark? I love those
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Old 12-01-2012, 01:29 AM   #9
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Most likely a bad or lose connection at one of the connectors. Probably only have to check the main connector at the resistor & the ones at the mode switch & the speed switch. Pull them & look closely at each terminal for signs of heat or arcing. Before you start take anything apart see if you can get the fan to start & stop by wiggling the connectors & harness (key on). That may help locate the problem.

Here is a link that has some troubleshooting & a wiring diagram for your HVAC. Note that the blower motor speed is controlled from the ground side of the circuit through the resistor, speed switch & the mode switch. In this case it was the motor that was bad but usually it is in the wiring or switches.


http://www.wranglerforum.com/f5/inte...ds-197598.html
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Old 12-01-2012, 02:10 AM   #10
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Quote:
Originally Posted by mrpotatohead
A few weeks ago I was tasked with troubleshooting and replacing a particular triaxial cable on an F/A-18... I'm pretty sure my blood pressure spiked and took YEARS off my life. Two things I hate: aircraft wiring and automotive interior plastic.
Damn wire chasers! I was an A/F mech on 18's from 89-93.
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Old 12-01-2012, 02:13 AM   #11
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Quote:
Originally Posted by mrpotatohead
A few weeks ago I was tasked with troubleshooting and replacing a particular triaxial cable on an F/A-18... I'm pretty sure my blood pressure spiked and took YEARS off my life. Two things I hate: aircraft wiring and automotive interior plastic.
Damn wire chasers, surprised you didn't just call the actuator bad!
I was a a/f mech on 18s from 90-93.
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Old 12-02-2012, 12:59 PM   #12
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I personally downed 5 jets due to bad servos in a two week time frame. I was hated
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Old 12-03-2012, 01:53 PM   #13
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Ok so I fixed it. The plug that connects to the vacuum side on the panel was missing. Someone before me took it out and connected the wires directly. I hooked the wires back up to the switch. Did some research and found that this plug is a common problem and melts. Anyone know how to keep it from melting again?
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Old 12-03-2012, 02:49 PM   #14
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Usually it is thought to be the blower motor drawing too many amps from age & wear. Also the wires for that circuit may be marginal causing excessive heat. Do some searching, there are diagrams out there where relays are used to take the heavy current off the wiring from the resistor as well as the switches. Be sure it is for the '99 & later circuits. The earlier yrs used a completely different circuit & the relays work for them too but have to be wired completely differently.

Here is one I have for the later circuit

Blower relay mod
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Old 12-03-2012, 03:01 PM   #15
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Thank you for the link. I will have to do that. Hopefully no more melted plugs.

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