What causes the relay connector to heat up and melt?
 

Well was working on my Jeep today and I noticed that the fan relay looked like it was melted a little. What would cause this? Can it be lack of ground or will it be a short somewhere? The fan turns on everytime the A/C compressor turns on. Maybe it needs more freon so the compressor can stay on longer or something??:wallbash:

I dont know about your relay melting problem, but the Fan should be on CONSTANTLY while the AC is on, not just when the compressor cycles.

def make sure enough freon, may be rusted ground or corroded ground, needs to draw more amps then gets hot

I will check the grounds then and take it to see if I have enough freon in the system.