Any clue what causes this? Meaning is the source of the heat coming from the current itself or something else? Just wondering if rigging up some type of heat shield could prevent this in the future.

 

Design flaw under sized wiring for amount of things drawing current thru single wire. Head light and blower motor resistor have similar issues. What I figure. Renix era are very under grounded also. This site can get your 1990 in tip top shape Hes also a member here.....http://cruiser54.com/

 

Right on. At least if it happens again it probably wouldn't be for a while I'm hoping, and now I know one more place to look if I ever have similar issues. Thanks again, I'm fairly confident (fingers crossed) that this will fix it, and like I said, I will definitely update here when I'm done to say for sure.

 

Once I get it running again and enough extra cash to upgrade to a 3 core radiator, my next project will be switching her to an open cooling system, which means a few more wires, ugh...haha. Just glanced so far, but http://cruiser54.com/ looks like a place I should park myself for a while so thanks for that freegdr!

 

No need for a 3 core radiator. An OEM system that's in top shape is more than adequate. Switching from a closed to open system I have no experience with but from what I've read here it's the way to go.

 

That's good to know thanks. Yeah no doubt, Ive heard many people say open systems can save a few headaches down the road. No clue about performance(cooling) differences if any, just mostly maintenance and potential problems with a closed system is why I want to change mine over. This XJ hasn't been given the love she needed in a while it appears so my goal is to replace as much as possible/needed before one thing leads to another. I bought a partial engine from a 92 XJ for the block that I plan to build into a monster and eventually swap it into this Jeep and make it a dedicated off road beast. Since I don't have much spare cash usually tho this will end up being a two or three year project I'm sure (if not longer). But I love older model XJs so its worth the time and money to me. By the way, if anyone needs anything off of that 92 motor I would be willing to part with anything I still have for the cost of shipping, with the exception of the head and intake manifold both of which I would sell stupid cheap or trade for other parts. ( not trying to make a sale here mods, just offering to help someone who may be looking if I can) Once I get new wheels on this one I will also have a set of 5 factory ones I will throw up in the classified section here before I list them anywhere else. (probably a few months down the road)

 

switching to an open system doesnt seem too bad...just a few necessary modifications that go along with it.
******* JUST A NOTE: This is not the only method, just the one I plan on doing. *******

 

By the way...here's the plug

 

Electricity is a complete mystery to most people, even mechanics.


That's exactly what it is, too much current for that device. No heat shielding will help.


Yep. It just a poor design.

The cure is to take the bigger current draw items and put them on relays, to take the heavy current out of that system. The typical automotive relay draws about a quarter amp, so if you have relays doing the heavy lifting, that connector should outlast the Jeep.

 

Sorry for my delayed response, got tied up with the real world for a minute there. I can totally understand why...haha. Not overly complicated to understand it seems, just very, very time consuming to try to learn it all. At least in my case. I'm just now trying to advance myself beyond the point of a simple bolt-on mechanic so I have a long journey ahead. I'm thankful for people like Cruiser54 and all the rest of you guys for helping to make that journey as smooth as possible. I wont go as far as saying I couldn't do it without you, but it would be a hell of a lot more time, work and wasted money...lol!



I also plan to add a second ground to the chasis as well, would doing this(not my reason for it) give any added protection with the ignition switch wiring issues at all? Sorry for any "dumb questions" guys, like I said...complete electrical noob here haha!

 

Did that fix the issue ?