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Old 03-30-2009, 09:25 AM
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TJ Wrangler Auto Electric Help Regarding The Blower Fan?

Hey, can anyone please help?
My demister blower fan on my 03 tj wrangler has stopped! No fan on any speed?
I have checked all the fuses and they seem o.k?
The fan switch, resistor, blower motor are all o.k?
I noticed that there is no active line on the wiring harness under the dash?
I mean when I pull the harness apart at the junction behind the glove box the part that runs to the blower and the switch is dead? No power coming through? I replaced the switch and still have the problem?
I located a main fuse running off the battery line and it is o.k?
The harness wiring dosen't look cooked, it looks as new?
The problem seems as though it could be just a fuse but they are all o.k.
Well at least the ones that I can see?
Could I be missing one somewhere not visible?
Has anyone had a similar problem?


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Old 03-30-2009, 10:58 AM   #2
 
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I have an 01 and the fan stopped on it. The fan connector on the motor under the hood rattled loose. According to the local dealer, that is a common problem with soft tops due to the fan being on "Hi" a larger percentage of the time.

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Old 04-27-2009, 07:55 PM   #3
 
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I have a similar problem. Sometimes when i crank my 2004 up, the airbag light comes on and at the same time the airbag light comes on , the blower motor for my a/c doesn't work at all. I don't know where to start looking.
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Old 04-27-2009, 08:57 PM   #4
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Off the top of my head. Loose plug/wiring on the motor, bad ground, or fried motor. Anything else would have to be traced with a schematic.
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Old 12-29-2014, 11:19 AM   #5
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Quote:
Originally Posted by J.A View Post
Hey, can anyone please help?
My demister blower fan on my 03 tj wrangler has stopped! No fan on any speed?
I have checked all the fuses and they seem o.k?
The fan switch, resistor, blower motor are all o.k?
I noticed that there is no active line on the wiring harness under the dash?
I mean when I pull the harness apart at the junction behind the glove box the part that runs to the blower and the switch is dead? No power coming through? I replaced the switch and still have the problem?
I located a main fuse running off the battery line and it is o.k?
The harness wiring dosen't look cooked, it looks as new?
The problem seems as though it could be just a fuse but they are all o.k.
Well at least the ones that I can see?
Could I be missing one somewhere not visible?
Has anyone had a similar problem?
Hi
Same problen. What is the solution
thanks
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Old 12-29-2014, 01:12 PM   #6
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Follow the voltage, either from blower connection back or fuse forward
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Old 01-03-2015, 08:27 AM   #7
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Same problem just started yesterday on my way to work. Need to diagnose because the lows this week are going to hit -10 here in Chicago. I'll add input as I find it seeing how this post is recent.

I'm going to start with my resistor because I know that component is bad. I'm thinking this will not be the fix.

03 tj 4.0
good luck
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Old 01-03-2015, 02:22 PM   #8
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This is a general procedure to troubleshoot the blower circuit. Some of the tests may apply to things you have already done but if you go through them step-by-step you should find the problem.

For '99-'04s: (For '05 & '06 the procedure is the same but the wire from the speed switch to the mode switch is dark blue/white rather then dark green. Not for '97 & '98s, the circuit for them is completely different.)


Make sure the blower motor tests good by putting 12v & a good ground directly to the motor. If good:

Make sure there is power to the blower motor*, and then everything from there is through the ground side. The ground path is from the blower to the resistor (except high speed which bypasses the resistor), to the speed switch (which directs which path through the resistor), to the mode switch (which closes the ground path in all positions except off which is the only position the blower is off) to ground.

After making sure you have 12v to the blower motor & good contact there you have to find where you are losing ground, which with 12v to the motor & a good motor, is what will keep it from running. You can jump the motor to ground to be sure the motor & connector there is good then work down the circuit. But when you lose all speeds the connector at the mode switch or the mode switch itself are the most common places of failure so check the 3 wire connector there for melting & signs of excessive heat then jumping the green & black wires from that 3 wire connector there is a good place to start after verifying that the black wire is grounded. When the mode switch is in any position except off it grounds the dark green wire through the black one. If jumping those wires (key on) gets all speeds & the connector is good the mode switch is bad. If no speeds, move to the speed switch. Check that 5 wire connector as you did for the 3 wire one. If you ground each of the 4 wires not including the dark green one (that goes to the mode switch) you should get each of the 4 speeds as long as the key is on. If yes, the speed switch is bad. If grounding the speed switch wires doesn’t get the blower running, especially high speed, go to the blower motor connector & recheck it carefully. If you do get high but are missing 1 or more of the lower speeds, the resistor is bad.

* If you don’t have power to the motor check fuse 8 behind the glove box & fuse 1 in the PDC in front of the battery. For ’99 only check fuse 11, not 1.
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Old 01-03-2015, 08:59 PM   #9
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Replaced blower resistor. It ended up solving all my problems
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Old 09-06-2016, 10:34 AM   #10
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I lost all speeds on my blower motor. Last yr i had to replace blower motor, resistor and speed switch to repair my system. Worked great since. I used your post to find a burnt gnd off of mode switch this time! THANKS for your great post! Really saved me some time and $. robbyg
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Old 09-06-2016, 10:49 AM   #11
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last post was a shout out to Rubi for my mrs! robbyg
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Old 09-06-2016, 11:34 AM   #12
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Umm, if memory serves me, there is a blower relay too. Could be it's defective.
Should be mounted behind the glove box, attached to the wire harness and case.
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Old 09-10-2016, 10:31 AM   #13
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Umm, if memory serves me, there is a blower relay too. Could be it's defective.
Should be mounted behind the glove box, attached to the wire harness and case.

Just experienced no blower in any speeds. It was relay behind dash near blower. Standard Bosch type relay.

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Old 09-13-2016, 08:45 AM   #14
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Good to know. Turned on my blower this morning and I only have one speed. HIGH lol. none of the others work. Will do some troubleshooting today.
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Old 08-17-2017, 01:38 AM   #15
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Help!

Hey guys,

I've attached two images of a wiring harness that needs replacing. My auto electrician told me that with some jiggling #4 now works but as you can see the harness is a little melted.

I'm also buying a new resistor off RockAuto but cannot find this 3 plug harness.

Can anyone link me to this type of harness to buy as it'll be impossible to get in Australia!

Thanks again!
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Old 08-17-2017, 02:14 PM   #16
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The harness & connector is quite expensive if even still available. The factory part # is 68080536AA, I think. It also has been available in the aftermarket & still may be. Use that # to search. I think in the $30-40 (US) range, as I recall.


Most of the guys just cut the connector off & wire the 3 wires directly to the switch with spade terminals. The terminals are very close to each other so you need to well insulate each one. Use shrink tubing, not electrical tape which tends to melt when it gets warm. Be sure to mark the wires & get them back on in the correct order.

These are grounding wires so even if they do short together the only thing that will happen is the fan or a/c compressor will start running even when “off”.

If after doing this you only have speed 4 you may have a bad resistor as well.
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Old 08-18-2017, 06:51 PM   #17
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68080536AA, as listed above, is the correct part number for the Connector repair kit. I bought one very recently on Amazon. It was sold by MyMoparParts.

Mike L.
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Old 08-18-2017, 06:52 PM   #18
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68080536AA, as listed above, is the correct part number for the Connector repair kit. I bought one very recently on Amazon. It was sold by MyMoparParts.

Mike L.
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Old 10-15-2017, 06:03 PM   #19
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Update, the plot thickens

So first I want to say, excellent guidance. We found out more than we initially knew......but I'm still a bit puzzled.

Blower motor:

-Jumped the ground and the fan started! (but had to manually close the relay to get it to run.)

Blower Relay:

-Tested fine out of the system when jumped 12V to it and grounded it.

-In the system it wouldn't work

Fuses:

#8 good

#11 good

Grounds:

-Two on the drivers side kick panel good

-Two on the passenger side kick panel good.

-Wire diagram shows G123 as the blower motor ground, but cant locate it physically.

Parts already thrown at it:

-New mode selector

-New fan switch

-New three wire connector

-New relay (old one tested fine too)

-New Resistor pack

It's got to be something simple that I am missing. Maybe I should just remove the kick panel grounds and wire brush them just for good measure. Any more help is appreciated.

Thanks!!!

Jim
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Old 07-18-2019, 02:37 PM   #20
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Going to revive this informative thread since I'm having an issue with mine.

My fan will not come on except for the very slow setting. Switching it to higher speeds has no effect. It does blow minimal air at the slow setting.

Does this same discussion/procedure apply to finding out what is wrong with mine? Thanks
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Old 07-18-2019, 03:42 PM   #21
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Originally Posted by dmatt13 View Post
Going to revive this informative thread since I'm having an issue with mine.

My fan will not come on except for the very slow setting. Switching it to higher speeds has no effect. It does blow minimal air at the slow setting.

Does this same discussion/procedure apply to finding out what is wrong with mine? Thanks

* Bold added, see below.



Yes, except in the other thread you thought it was not coming on at all. So if you have low speed (or any other speed than high) but it turns off on the others you can skip some of the checks posted in #8 above. (see below)

* On the other hand if it stays on low as you turn the knob (as highlighted from you post) the knob may be cracked or damaged where it pushes into the speed switch shaft & the knob may not be actually turning the switch. In that case pull the knob & turn the shaft with pliers to see if you get the other 3 speeds. If it turns freely without getting the distinct detents for the other speeds the switch is probably bad. Test it further to verify. (see below)

Here is the test for the speed switch only from #8.

If no speeds, move to the speed switch. Check that 5 wire connector as you did for the 3 wire one. If you ground each of the 4 wires not including the dark green one (that goes to the mode switch) you should get each of the 4 speeds as long as the key is on. If yes, the speed switch is bad.

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