Well, things have been going well with the 95 XJ recovery project. I have clear coolant after 6 or 7 flushings, I have brakes after some creative bleeding.

Now, the turn signal / emergency flasher fuse is blowing. This just started today after a short off-road ride. The fault is intermittent, because I can replace the fuse and everything works for a while. This is one of the large under-hood fuses (20A) that run about $4 each.

I was hoping there may be a common weakness in 95 XJ signal light wiring that has been discovered by the many XJ owner/members of this forum, and I can check that one spot rather than try to track down a short / ground that isn't there most of the time.

Thanks in advance for any info....

 

There is a plug for the front lights that is between the air filter box and the fender, they get corroded and dirty over time.

 

What Cliffy said.
The electrical plug drivers front, ahead of the air box, behind the light.
Notorious for corrosion!

 

Does the corrosion provide a path to ground that can blow the fuse? I should be able to tell when I look, just haven't had a chance yet, being lazy on Labor Day. Heading out to O'reilley's shortly to pick up a fuse or two. $4 is a high priced fuse.....

 

There is a ground wire in the harness so it is possible. I deleted my plug all together when I added my headlight harness upgrade.

 

Well, I found it, but it took way longer than I hoped. The fuse was actually blowing when the brakes were applied, specifically when the brake light switch operated. There's a big wire bundle that comes through the firewall just above the accelerator pedal. Once inside, the bundle turns toward the driveline tunnel / transmission hump. The "bow" of the bundle lies against the front edge of the ABS controller, which is an aluminum case. The bundle had pressed and rubbed against the ABS case so long, the tape around the bundle and the insulation of at least one wire was worn through & grounding against the case. A piece of split foam rubber tubing with a tie-wrap to hold it in place was the fix.

 

Nice find.

 

Good work.