Searched multiple threads, but didn't find any with my exact problem.

I can do just about anything I need to to my rig, but when electrical problems happen, I jump on the little, yellow bus. I've seen this similar issue on some threads, with answers like a bad clockspring, or water in the horn, etc. But I don't think either of those covers my dilemma.

I bought a Wolo Bad Boy and did not change out the fuses. I took out the factory horn, hooked up the Wolo, and it sounded like an old man coughing up phlegm. I unhooked it, checked the connections, then hooked it back up. Nothing but one click from the fuse box, then silence. Took the Wolo off, hooked the factory horn back up, and the same thing. Single click from the fuse box, then nothing. M22 and M23 fuses are both still in tact, and I have no warning lights for air bag, or any of the other common symptoms of a bad clockspring. Obviously I'm going to switch the fuses out and try again, but wanted to get some ideas as to what the issue might be, first.

 

The aftermarked horn probably draws a lot more power than the stock horn. More power=more loud.

The Jeep has a power control box that turns everything on/off with solid-state relays (fancy words for a big transistor). Solid state relays have a limit to how much power they can handle. Beyond that limit, they will self-destruct. I hope not, but this may be what happened to yours.

If that is what happened to you, then this is 20-20 hindsight, but there is a way around it. Use a relay that gets its power straight from the battery. Then use the old horn wire to turn the relay on/off. This works for pretty much any electrical toy that uses more power than the stock system. Lights, for example.

 

The control side of the horn relay is controlled by computer chip.
The load side of the relay gets it's power directly from the battery.
The op said he hears a click from the TIPM when he pushes the horn button. That's the mechanical horn relay closing.
The relay control side gets power independent of the fuse.
The horn relay feeds battery voltage to both the M22 and M23 fuses.
In domestic JK's, the load side of fuse M22 feeds power to an empty socket in the connector under the TIPM.
If he hears the click when he presses the horn button, my guess is he blew the horn fuse, or fried a wire or connection.

The wire that goes from the TIPM to the horn is 20 awg. The fuse is 10 amps.
If the horn the op used is the one I looked up, the instructions say to use 16 awg wires, and a 20 amp fuse.
That could be the problem.

 

This is what I was thinking.

I did some research here before my purchase and others used this horn and simply "plugged and played". The instructions provided, and the connections on the horn, furthered that line of thinking. The only thing I can think of is a fried wire, since both the M22 and M23 are not blown. Won't be able to do anything with it until Sunday, so hopefully it won't end up being something serious.


Edit: Thanks, ronjenx. After checking your fuse box diagram again, I realized the diagram I had was mislabeled (the one on my lid is unreadable). I pulled the M23 and sure enough, it was blown. Picking up some 20's on Sunday and hopefully then I'll have a horn that doesn't sound like someone stepping on a bunny.

 

Installing a 20 amp fuse in a circuit designed for a 10 amp fuse is not a good idea.
The fuse blew because it was protecting the circuit in the JK.

Look at your instructions and see what wire size it says to use to feed the horn.
The JK has a 20 awg. I believe the instructions call for at least 16 awg, which is bigger than 20.

 

No mention of wiring in the instructions. Says simply plug and play. Checked the other threads here with that particular model and everyone said they simply upgraded the fuse, plugged it in, and they were good to go.

 

X2 on not using a bigger fuse. If the JK uses 20 awg wire for that circuit, a 10 amp fuse is maximum.

Possibly something has changed with that horn. (Made in China?) in any case, if a 10 amp circuit won't hold the horn, use an auxillary relay. With a relay and 12 awg wire (20 amp fuse) the horn will run louder anyway.

 

Well, put a 20 in both slots, plugged it in, and... it works just fine. No issues whatsoever. Actually had to use it a couple of times this afternoon, on people who had fallen asleep at a light. It woke them up nicely.

 

That's one safety issue solved (no horn) and another created (the circuit is no longer protected by the correct size fuse). If you really are OK with the risk of running an oversize fuse, at least change to a 15 amp to reduce the risk of fire somewhat.