Ok I've read about 100 post involving heaters but still can't figure this out. Ok so i got my 2000 tj this summer and the heat/ac only worked on high speed. Before I was able to get to replacing the resistor the high setting stopped working. At the same time the lights on the heater panel went off. Also now when I rotate the vent switch I have an odd hiss sound from behind the The heater switches that get louder the closer I get to the off selection. And when vent is high and vent selection is on defrost the lights come back on. The changed the resistor and no melting on the wires. Any help will be appreciated.
The brown vacuum hose is for the floor actuator. There should only be vacuum there when the floor vent is active which should only be with the a/c mix, floor heat & defrost/floor heat positions. I don't see how that would affect any of your electrical problems but wiggling the wires indicates a loose connection or bad switch somewhere related to where you are wiggling those wires. That could well be at the mode switch connection (3 wires next to the vacuum connections) that can cause all the fan speeds to be out.
Thanks for your input. The lights don't work still but I can live without that. I have heat at the moment and at 20 degrees here I'm grateful to have it. But I plan to dig farther into it when it warms up
I kinda have the same problem with my 2000 sport, I didn't have the 3rd speed on the fan, but everything else worked, then came out one day and had nothing I finally got the vent working and now I have nothing and very little heat coming out
You can add my '05 LJ to the list. All modes work but all get air moving on the high fan setting. Will be watching to see how you get to a permanent fix. I haven't had a chance to get behind the panel on mine yet.