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Posted

Long time ago, the first time mine caught on fire, I just pulled a full one off a close year from a Cherokee at a junkyard. There were a couple differences but I can't currently remember what they were. MAybe something with the taillights. Nothing that important though. And I also had an 88 auto at the time. My advice, take many, many pictures as you pull it off the donor vehicle. I went to a pick and pull but nowadays you should just be able to search online and just have them pull it for you and ship it. Might cost a little more but worth the headache.

Posted

The easiest fix is to obtain a bunch of rolls of appropriate wire in guages that are at least as heavy as the OEM.  Multiple colors will help, as will a wiring diagram for your model year.

 

Do this one at a time:

1.  Cut out the burnt/melted wire at each end of the damaged area.  
2.  Using a wire of gauge the same or maybe one size larger, splice in a replacement wire to replace the cut section.

3.  DO NOT use butt splice crimp connectors.  I have seen too many of those wind up creating high resistance connections that causes further wiring melting.

4.  Either use solder-type butt splices that use low temperature solder (that can be activated by a heat gun) or do the old fashioned solder and heat shrink tubing to restore each connection.

 

I know this sounds like a PITA, but early XJ/MJ wiring was sorta marginal, and fixing wires that were flakey with improved current carrying capacity (and reduced chances of heat damage) is a good thing.

 

My fuel injector harness on my XJ HO engine developed this issue due to engine heat, and after I discovered how pervasive the damage was, I bit the bullet and fixed all the suspect wires.  Underhood (or under dash) wiring fires are no joke.
 

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