94 yj Heater/blower HELP!!

[hoop]

Please tell me someone else has had this problem or knows what I need to do to fix it. My heater blower fuse keeps melting(25amp) in the fuse block. I've taken it out and the holder is sloppy and charred. Checked voltage on the female holder and it seems to vary a lot up to 17v. also if you watch the fuse as you move the switch you can see the fuse glowing on the left side as you look at the fuse block from the drivers floor. Today the fuse died and took with it all my gauges. drove the jeep 10 miles and shut it off, pulled out the fuse above the heater fuse ( 15amp backup lights, dash) fuse was fine, put it back in and all was well with the gauges but haven't tried the heat. I've been melting fuses for a year now and finally got off my a** to figure it out. Any help is appreciated...

 

[rattlecanpaint]

17 volts is WAY too much. Sounds like the voltage regulator on the alternator. Check the voltage across the battery with the engine running. If more than 14 or so, you need an alternator. If 14 or less, you may need a blower motor. We had a 7 Series BMW do the same thing you are discribing and it turned out to be the blower motor drawing right at the limit of the fuse. Not enough to blow the fuse, just get it hot enough to melt the fuse block, top of the fuse box, micro filter housing and microfilter. Smelled HORRIBLE inside for a while.

 

[jeepn-jason]

Another thing to ck....make sure the prongs that hold the fuse in place arent bent out from someone using fuse taps. I see this a lot on different vehicles.