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Old 03-05-2017, 11:49 AM
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Blower motor preventative fix

Blower motor works fine on my tj. I'd like to prevent the melted wires/connector or losing a/c or heat on a long trip.

There seems to be many opinions out there about how to fix the problem after it has happened.

There isn't a full consensus, but many point to the blower motor itself as the culprit. If the blower motor is replaced when everything is working is there agreement that the system will then last for a good number of years?

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Old 03-05-2017, 12:12 PM   #2
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I suspect that melted connectors are more than likely caused by poor connections than anything else. Corrosion occurs over time, resistance increases and plastic melts.

I dealt with a similar problem on a Dodge truck. Replaced a melted connector and the blower motor. Within a few months, connector melted again. Next step was to eliminate the connector by soldering the harness directly to the blower resistor. No problems since.

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Old 03-05-2017, 01:11 PM   #3
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I suspect that melted connectors are more than likely caused by poor connections than anything else. Corrosion occurs over time, resistance increases and plastic melts.

I dealt with a similar problem on a Dodge truck. Replaced a melted connector and the blower motor. Within a few months, connector melted again. Next step was to eliminate the connector by soldering the harness directly to the blower resistor. No problems since.
^^^I agree, bad connections are the prime suspect in almost all cases. Does the blower motor draw more current as it gets older?..Sure, but the issues that I've witnessed are due to poor connections in the switch connector.
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Old 03-05-2017, 01:17 PM
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^^^I agree, bad connections are the prime suspect in almost all cases. Does the blower motor draw more current as it gets older?..Sure, but the issues that I've witnessed are due to poor connections in the switch connector.
So, if everything is currently working, what steps are recommended to prevent an unexpected failure.
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Old 03-05-2017, 03:05 PM   #5
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I heard it is due to the blower motor pulling more power than designed - could be age, water, leaves and grime etc

After I get mine fixed I am prob going to put a 15 amp fuse in and see if it blows (so to speak).
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Old 03-05-2017, 07:21 PM   #6
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So, if everything is currently working, what steps are recommended to prevent an unexpected failure.
If you live in L.A., I wouldn't worry about it. Most of the ones I've seen go south are in cold and wet climates and are due to corrosion and where the heater is used constantly. I'm from northern CA, and my jeep has 159k on it and has never had an issue with the heater motor or melted plug.
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Old 03-05-2017, 07:53 PM
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If you live in L.A., I wouldn't worry about it. Most of the ones I've seen go south are in cold and wet climates and are due to corrosion and where the heater is used constantly. I'm from northern CA, and my jeep has 159k on it and has never had an issue with the heater motor or melted plug.
I'm in so cal. I haven't taken the time to survey where most complaints are from.

Maybe it's silly, but I cringe sometimes when I'm using my a.c. or heater, thinking is it going to go out during this drive.


Anyone out there have problems with blower motor, switch, melted wires etc who live in AZ, NV, TX, or CA?
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Old 03-05-2017, 09:03 PM   #8
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Mine gave out a couple months ago. It works on lowest and highest settings and that's enough for me lol. Is it bad to not fix it?


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Old 03-05-2017, 09:12 PM   #9
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Mine gave out a couple months ago. It works on lowest and highest settings and that's enough for me lol. Is it bad to not fix it?


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That's likely the switch.
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Old 03-05-2017, 09:23 PM   #10
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So I'm not hurting anything by leaving it like that?


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Old 04-06-2017, 07:24 PM   #11
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Good stuff.

My entire heating system went (connections, blower, fuse) and after replacing all of it? My controls seem to need replacing as well. I had a thin, but thick white smoke coming out from behind the vent knob, I shit you not! Must be a fault or something :'(

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Old 04-06-2017, 10:27 PM   #12
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I'm in so cal. I haven't taken the time to survey where most complaints are from.

Maybe it's silly, but I cringe sometimes when I'm using my a.c. or heater, thinking is it going to go out during this drive.


Anyone out there have problems with blower motor, switch, melted wires etc who live in AZ, NV, TX, or CA?
I'm SoCal.

Recently started having issues with the vacuum selector switch.
Noticed originally, recycled A/C position went out, but still worked on all other settings(A/C and heater). When I say it went out, I mean I had nothing. Function and fan both originally quit on the recycled air setting only.

Next day, while driving around town, the A/C and fan just randomly quit. A few minutes later, back on. Then minutes later, we're off again, etc... Tried wiggling/turning the knob while driving to see if it was possibly a dirty contact or loose switch. No effects from this Hi-Tech process(lol), but if anyone would like my personal technique, I can do a write-up.

Once I returned home, I extracted the HVAC and removed the vacuum selector switch. It was apparent that it had experienced some heat as it was slightly fused to the internal part of the module plate.

So, I'm assuming I need a new switch. Okay that should be easy. Except you can't buy just the vacuum switch on an '05 or '06. Gotta get the entire module. Well I'm okay with that too, as long as it's "the fix."

But would it be a temporary fix??? What's causing the switch to get hot???
I've read where old blowers can over amp, and cause the fan switch to get hot, but would it have any effect on the selector switch???

Finally, just to keep the symptoms updated, when I re-assembled the bad switch in the HVAC, I can't get any of the functions on the selector switch to work now; randomly or not. I can hear vents opening and closing as it rolls past the different function settings, but no A/C kicking on and no fan at any speed. Although, if I turn the selector to the off position(O), I can run the fan on all four speeds as the selector defaults to defrost. I've read this is a factory safety default.

Anyways, I went ahead and ordered a new HVAC module and will install when it arrives next week. (fingers crossed)
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Old 04-11-2017, 11:13 PM   #13
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^^^^Installed the new HVAC module and everything is up and running once again.

Going to be closely monitoring the switch for any signs of heat in the near future. Hopefully, just a random failed switch and not in relation to the overheating failures of the fan speed switch.

To the OP,

Did you end up replacing the blower motor for preventative, or "run what ya brung?"
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Old 04-14-2017, 05:15 PM
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^^^^Installed the new HVAC module and everything is up and running once again.

Going to be closely monitoring the switch for any signs of heat in the near future. Hopefully, just a random failed switch and not in relation to the overheating failures of the fan speed switch.

To the OP,

Did you end up replacing the blower motor for preventative, or "run what ya brung?"
I went through and looked at the connectors and wiring. Everything looked good. Put a little dielectric grease in the connectors and called it a day.

It still runs fine. (But for the new leak in the evaporator.)

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