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Smoking wires from AC relay

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Old Aug 15, 2025 | 02:42 AM
  #1  
CherokeeFrenchImports's Avatar
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Joined: May 2021
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From: Lebanon
Year: 1990
Model: Cherokee (XJ)
Engine: Renix 4.0
Default Smoking wires from AC relay

I have a 1990 limited.

So my AC clutch wasn't kicking in. After replacing the AC relay and opening the key contact the wires to the relay started smoking and melting terribly. I turned of key asap and ripped the relay out. So now I'm left with an every bigger mess. I have two wires which went into the ac relay completely stripped and melted. And I also found a bundle of other wires in the loom which have been cut by a previous owner. I'm trying to get the whole jeep back to stock. Can anyone tell me why they would melt up like that, was the relay wired incorrectly?

This wouldn't cause any kind of lasting damage right? Since the wires are stripped I haven't started the jeep up since.



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Old Aug 15, 2025 | 05:50 AM
  #2  
Ricthewrench's Avatar
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From: Ortonville, mi
Year: 97
Model: Cherokee (XJ)
Engine: 4.0
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Wiring is a pita! Downloadthe service manual for your vehicle and start tracing wires my friend. Replace old crummy wires with new, dont just splice in a piece. Every connection adds resistance, resistance is heat. On the positive front you would be learning electrical and we all need that. Good luck
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