NHTSA Complaint #10476993 — 2003 VOLKSWAGEN BEETLE

THIS PARTICULAR ELECTRICAL PROBLEM WITH VW NEW BEETLES HAS BEEN REPORTED IN ONLINE VW FORUMS HUNDREDS OF TIMES. THERE IS A SMALL PLASTIC FUSE BOX THAT IS ATTACHED AT THE TOP OF THE VEHICLE BATTERY IN THE ENGINE COMPARTMENT. IT CONTAINS A SERIES OF FLAT METAL FUSES OF VARIOUS AMPERAGE, AND IS ELECTRICALLY FED BY A CABLE DIRECTLY FROM THE ALTERNATOR. ONCE AT THE FUSE BOX, THE ELECTRICITY IS BRANCHED TO OTHER CIRCUITS BY CONNECTION TO A BUS. BUT THE MAIN FEED FROM THE FUSE BOX IS TO THE BATTERY BY AN AUXILIARY CABLE, BRANCHING OUT FROM THE FUSE BOX, CONNECTED BY THE ALTERNATOR CABLE/FLAT FUSE AT ONE END (IN THE FUSE BOX), AND DIRECTLY TO THE BATTERY POSITIVE AT THE OTHER END. THE PROBLEM IS THAT THE ENTIRE FUSE BOX ASSEMBLY FREQUENTLY MELTS INTO A GLOB OF PLASTIC, AND REPRESENTS A SIGNIFICANT FIRE HAZARD. I HAVE OWNED TWO NEW BEETLES (2003 & 2004), AND HAVE EXPERIENCED THIS PROBLEM FOUR TIME BETWEEN THE TWO. MY OWN INVESTIGATION INTO THE CAUSE(S) HAS SHOWN ME THAT IF THE VEHICLE BATTERY IS DISCHARGED, AND THE ALTERNATOR ATTEMPTS TO RECHARGE THE BATTERY AT A HIGH RATE, THAT ONCE THE ELECTRICAL CHARGE ENTERS THE FUSE BOX VIA THE ALTERNATOR CABLE, THE AUXILIARY CABLE IS INCAPABLE OF ALLOWING THE ELECTRICITY TO PASS ON THROUGH TO THE BATTERY. THE EXCESS ELECTRICAL BUILD UP IS DISSIPATED AS HEAT, AND THE FUSE BOX MELTS. IT IS ANALOGOUS TO BRINGING IN WATER THROUGH A FIRE HOSE (THE ALTERNATOR CABLE), AND THEN TRYING TO FUNNEL ALL OF THE WATER INTO A STRAW (THE AUXILIARY CABLE). IT WON'T FIT. IT APPEARS THAT THE AUXILIARY CABLE IS OF INSUFFICIENT SIZE AND METAL TYPE TO HANDLE THE ELECTRICAL CHARGE. IN ADDITION TO THE GENERIC FIRE HAZARD, GIVEN THE FUSE BOX LOCATION, ANY LEAKING FUMES (HYDROGEN) FROM THE BATTERY WHICH COME INTO CONTACT WITH A FUSE BOX SPARK/FLAME COULD CAUSE THE BATTERY TO EXPLODE. PLEASE ADVISE. *TR