NHTSA Complaint #10533464 — 2008 FORD F-150

DURING THE SPRING OF 2013 THE HVAC BLOWER MOTOR SPEED SELECTOR SWITCH WAS PRODUCING THE SAME AMOUNT OF AIR ON POSITION 4 AS IT DID ON 3. I REPLACED THE BLOWER MOTOR RESISTOR, BUT THIS DID NOT SOLVE THE PROBLEM. I TOOK OFF THE DASH TRIM BEZEL TO GAIN ACCESS TO THE REAR OF THE HVAC CONTROLS, AND I WAS SHOCKED TO FIND MELTED & BURNT PLASTIC. A COUPLE OF THE WIRES WERE BROWN FROM WHAT I CAN ONLY ASSUME WAS A SMALL FIRE. WE HAVE A 10 MONTH, OUR FIRST CHILD, AND MY HEART WAS RACING AT THE FEAR OF A VEHICLE FIRE AND GETTING OUR BABY GIRL OUT SAFE IN TIME. SHOULD A FUSE BLOW PRIOR TO THIS FAILURE? I DID SOME LOOKING ONLINE, REPLACED THE SWITCH AND WIRE HARNESS PIGTAIL. IT WORKS FINE NOW, BUT I DISCOVERED THE PROBLEM, AND WHY SO MANY FORDS ARE EXPERIENCING THIS ON THE WINDOW CONTROL SWITCHES & BLOWER MOTOR CONTROL SWITCHES. IT'S BECAUSE BOTH USE THE SAME 4 WIRE BLADE PLUG. AND THE WAY IT IS ASSEMBLED IS THE CAUSE. THE TERMINALS NEED TO TIGHTER AROUND THE BLADE CONNECTION. ALSO, THE PORTION THAT IS CRIMPED WHERE THE WIRE ATTACHED TO THE TERMINAL SITS OFF CENTER AND ASSEMBLED BACK TO BACK. IF IT WAS ASSEMBLED WITH THE CRIMP ON THE INSIDE IT WOULD CREATE A BIGGER GAP AND REDUCE THE RISK OF VEHICLE FIRES. I TOOK A BUNCH OF PHOTOS AND STILL HAVE THE ORIGINAL SWITCH IF YOU CARE TO EXAMINE IT. *TR