Decided to repair my faulty blow motor speeds. Only works on high.
Ordered the resistor kit from Advance. Along with the resistor comes a new plug and splicers in case your OEM plug wires melted. Mine were. There are four prongs on the resistor and four sockets on the plug. One of the sockets on the old plug has two wires. The new plug has one for this socket. Added to this quagmire is the fact the OEM wires have a much thicker gauge then the new wires.
The guys at Advance suggested I find a 3 prong splicer to connect the two OEM wires and the new wire. One of the two wires controls the low and medium speed, while the other controls the high speed.

Has anyone dealt with this issue?

Thanks
93 XJ Sport

 

I've had to replace 2 before on previous jeeps, never had melted wires though; I was fortunate enough to just have to replace the resistor and that was it. How bad are the wires?

 

The raised socket on the plug (1 of 4) was completely burned off of the plug. This was the socket that had the two speed wires attached

 

The old

 

The new

 

Never dealt with this issue but am familiar with what you are talking about.


Doing several searches at the common parts stores I found that the wires for their connector(s) are too small. Your system requires AWG 12 wires, not 14 or 16. The smaller wires will cook.

 

Ok thanks. I'll call them back and see if they can get the correct plug.
Thank you for your help

 

Ok thanks. I'll call them back and see if they can get the correct plug.
Thank you for your help

 

Well like you said they don't carry the awg 12 gauge plug. My next step would be to check the junkyard. He said before I do that, I should ask on here if anyone knows a part # or another vehicle that he could cross reference to get the plug I need. I know this is a long shot.
I'm actually surprised that the correct plug is so hard to find.....

 

I chatted on-line with these folks about what AWG wires are used in the HVAC Blower Resistor Connector they are selling. They said it would take 24-48 hours to find out from the manufacturer. 10 to 1 says they are 14 gauge.


http://www.carid.com/1992-jeep-cherokee-air-conditioning-heating-parts/standard-hvac-blower-motor-accessories-44854127.html


If this link won't open, copy it and paste it to your browser.


These connectors can be de-pinned and new wires inserted with the proper terminals and AWG 12 wires. But would require a special crimper for the terminals, although they can be crimped using needle nose pliers and common crimper.


I have half a mind to buy a few of these connectors and rewire them, then sell them on the forum.

 

After giving the burnt wires a closer look, they used a tap splice like this new one I found. Two wires go in, one comes out the other end. The currents are connected inside, with the result being low, med and hi speeds.

 

While I was at the hardware store I found these 12-10 disconnects which fit onto the prongs of the resistor.
Is there any harm in foregoing the plug all together and plugging the wires in to the resistor with these new disconnects? Does the plastic housing serve any real purpose?

 

Those will probably work okay. Make sure you mark down what color wire goes where beforehand.

 

CCKen - thanks for taking the time to look into this. I will let you know how this works out. Maybe there is more than one way to skin a cat

 

And here she is, minus plastic plug housing. The wires dont have much slack due to multiple (2) cuttings, so I'll keep an eye on her for awhile.<br/>What's important is, we now have low, med, med-hi and hi. SWEETNESS <br/>Just in time for the hot weather, which im in the process of getting A/C recharged. Replaced a leaky A/C hose now i just need to fill her up.<br/><br/>Thanks again bud!