NHTSA Complaint #10233579 — 2002 VOLKSWAGEN PASSAT

MY 2002 VW PASSAT INITIALLY BLEW THE #5 FUSE WHICH CONTROLS THE A/C, STEERING WHEEL ITEMS (HORN, VOLUME CONTROL, ETC.) AND ITEMS ON THE DRIVER SIDE SUN VISOR. THE FUSE WAS REPLACED AND SUBSEQUENTLY I EXPERIENCED SMOKING IN THE AREA OF THE SUN VISOR. REMOVING THE VISOR, I NOTICED FRAYED WIRING AND BURNT WIRING INSULATION. IN ADDITION THERE WAS SPARKING INSIDE THE ROOF AREA. I TOOK THE CAR TO THE DEALER AND THEY CUT THE FRAYED WIRE AND TAPED IT UP, WITH A MORE COMPLETE REPAIR TO COME IN A COUPLE OF DAYS. DRIVING THE CAR HOME LATER THAT DAY THE CAR STARTED SMOKING AGAIN WITH THE ADDITION OF CRACKLING SOUNDS. I HAD THE CAR TOWED TO THE DEALER THAT EVENING. THE DEALER IS NOW LOOKING AT THE WIRING AND HAS FOUND AT LEAST ONE WIRE LEADING FROM THE VISOR AREA ALL THE WAY DOWN TO THE FUSE BOX WHICH IS BARE BECAUSE IT'S INSULATION HAS BEEN BURNED OFF. THE FUSE THAT SHOULD HAVE BLOWN WAS MELTED INTO THE FUSE BOX. THE BURNED WIRE HAS ALSO BURNED OFF INSULATION ON OTHER WIRES WHICH WERE TOUCHING THE DAMAGED WIRE. THE DEALER IS TRYING TO TRACK DOWN ALL THE WIRES THAT MAY HAVE BEEN DAMAGED. CURRENT COST IS APPROXIMATELY $2400 WITH VOLKSWAGEN AGREEING TO PICK UP $900 OF THE COST. BASED ON INTERNET RESEARCH, THERE HAVE BEEN OTHER REPORTS OF FRAYED WIRING IN THE VISOR AREA OF THE 2002 PASSAT. I HAVE NUMEROUS POSTINGS BY PEOPLE WHO HAVE BLOWN THE FUSE AND HAD THEIR VISORS REPLACED. OTHERS HAVE PULLED DOWN THE VISOR AND TAPED UP THE FRAYED WIRING IN THEIR VISOR. I BELIEVE THIS TO BE A DESIGN OR MANUFACTURING FLAW AND I BELIEVE THAT MY VISOR WIRING HAS BEEN FRAYING FOR SOME TIME PRIOR TO THE CATASTROPHIC FAILURE. *TR