Ignition switch melting hot / 96 cherokee
 

96 Cherokee Country
4WD
AC/In-line 6
310,000 Miles

Heater/AC blower stopped working except for high speed. When running the blower the ignition switch got melting hot (smoke from steering column). I replaced the blower resister. The variable speeds are now working but the ignition switch still gets extremely HOT. It gets very warm when switch is at it's lowest setting and hotter as the fan speed is increased. I have removed the steering column shroud and found the the RED and BLUE wires almost burnt in two. I replaced the wiring harness. It still gets VERY HOT. For fear of fire I have unplugged the blower resistor until I find a resolve so now the fan does not work except for when I switch to high.

After some research I have found this is a problem with the 96 but I have not found any solution to the problem.

Note: I do remember the blower would make a very loud screeching noise prior to blower resistor going bad. Thank you in advance for your help.

you probably have a blower motor going out which is pulling too much amperage through the ignition switch.

I would have the wires running through the ignition switch activate a relay to power the blower motor from a separate fused circuit.