NHTSA Complaint #10411667 — 2005 VOLKSWAGEN JETTA

WIRING HARNESS BETWEEN THE BODY AND THE DOORS FLEXES DURING OPENING AND CLOSING OF THE DOOR. THE WIRE COATING BECOMES BRITTLE WITH AGE AND CRACKS CAUSING STRESS POINTS IN THE WIRE LEADING TO BREAKAGE OF 1 OR MORE WIRES IN THE HARNESS LEADING TO INOPERABLE CONTROLS AND ELECTRONICS IN THE DOOR, POSSIBLE ELECTRICAL SHORT, AND POTENTIAL FIRE HAZARD. THIS FAILURE TENDS TO OCCUR AFTER A COUPLE YEARS OF USAGE. THIS PARTICULAR VEHICLE FAILED AT 65,000 MILES. USUALLY THE DRIVER'S DOOR FAILS FIRST AS IT IS USED MOST FREQUENTLY. THIS EQUIPMENT INCLUDES BUT MAY NOT BE LIMITED TO WINDOW CONTROLS, DOOR LOCKS, DOOR OPEN SENSOR, AIR BAG SYSTEM CRASH SENSOR, TRUNK RELEASE SWITCH, FUEL DOOR RELEASE SWITCH, DOOR MIRROR ADJUSTMENT, MIRROR TURN SIGNAL INDICATOR, MIRROR HEATING ELEMENT. WIRING HARNESS MUST BE REPLACED WHICH COSTS APPROXIMATELY $150-$200. HARNESS SHOULD BE REDESIGNED WITH LONGER WIRES TO AVOID STRETCHING OF THE WIRE AND WIRE COATING MATERIAL CHANGED TO AVOID BRITTLENESS WITH AGE AND WORK HARDENING. *TR