CCKen

A NAXJA member replaced his harnesses because the corrosion was so bad in the connectors. This would be a real task because I think you would have to remove the dash and the HVAC Unit to get at all the harnesses involved. He did it though.

Solder splicing is the preferred method but if you are not excellent at it you may introduce problems through cold solder joints.

You must be proficient at crimping butt splices as well.

You will be splicing 27 wires from C4. There are four different wires sizes that you must be aware of. You'll need Yellow and Red/Pink butt splices (lots).

Stagger the wire cuts/butt splices so you don't end up with a ball of splices. Use "weather Proof" butt splices. They have heat shrink ends on them.

Concerning the other connectors being corroded: If only the pin cavities are corroded and not the inside of the connectors, you may get away with removing the corrosion from the pin cavities using white vinegar and scrubbing them with an acid brush (Home Depot, Lowes, Harbor Freight), then flushing out the connectors with CRC QD Electronic Cleaner (many times).

Get a C4 and JB from a '98 thru '01 XJ. The pinouts for C4 are the same for these years. '97 is a little different.

I'll post a pinout of C4 when I get a chance so you can see what size wires go where, then you can select the proper butt splice size for that wire.

Jeepkid922

Should I sotter and shrink tube the new c4 plug I have or should I use butt connectors?

Jeepkid922

Ok cool I will probably use butt splices, I picked up a jb from a 99 and all the plugs, thing looks basically brand new, I was soldering today but I think I am just going to use butt splices I will finish tomorrow.

Jeepkid922

Some of the wires are oxidized.. What should I do? Replace the oxidized wire or just clean it and use it?

CCKen

Which wires are oxidized, the wires on the replacement connector(s) or the orignal wires in the Jeep? If they are the original wires in the Jeep, you should find out where the wires look free of oxidation and splice in new wires.

How did the rest of the original connectors look after cleaning them?

98-01 JB C4 Pinout.

You can determine wire size by looking in the column headed "Circuit".. The first set of letter/numbers are the circuit ID, the next number is the wire gauge, and the next set of letters are the wire colors.

cpefy3

I actually had this same problem and had to do this same exact thing. It is a pain in the *****, but well worth it. Make sure you solder and shrink wrap your connections. Also, I would try and track down how moisture is entering this area to cause the corrosion. I would suspect a leaking windshield, although on mine I had moisture running down my A pillar from a hole I had drilled in the roof to run the wires for my auxiliary lights.... best of luck

CCKen

I forgot to mention...

Look under your driver seat and see if the Airbag Control Module is mounted there.

Your first post said you had an Airbag light on.

If it's still under the seat and your Heep went for a swim the ABCM may be a ball of corrosion like your JB.

Jeepkid922

Thanks for all the help CCKen, it turns out to be the JB, i used solder and shrink wrap on some of the wires and weather proof but splices on some too, got it all back together and everything works, jeep even seems to run better but who knows, everything works as it should including horn, door locks, door windows, blower motor turning off when ignition goes off, cluster works great same with radio.. Took a little bit to figure it out but glad I did.

Jeepkid922

Oh and I don't think it took in water, it could of but there is a hole looks like the previous owner popped out a rubber plug to run a antenna to the radio, pretty sure that's where all the water and mud came from over time just corroded the jb, and the air bag module the plug doesn't have any sign of corrosion on it either, my air bag light is now off too.

Jeepkid922

Thanks man everything works now.

CCKen

Good work.

You are now a member of the infamous corroded JB Club.