NHTSA Complaint #10547473 — 2003 VOLKSWAGEN JETTA

ALL WARNING INDICATORS (ABS, CEL, AIRBAG, ECP, BATTERY AND OTHER INSTRUMENT DASH PANEL LIGHTS) WOULD FLICKER REPETITIVELY UNTIL THE CAR LOST ALL POWER. AFTER INSPECTION OF THE ENGINE COMPARTMENT IT WAS FOUND THAT THE ALTERNATOR CABLE THAT ATTACHES TO THE FUSE BOX LOCATED ON TOP OF THE BATTERY WAS MELTING THE FUSE BOX AND CAUSING POWER DISTRIBUTION PROBLEMS. THE VOLKSWAGEN DEALER RECOMMENDED THAT THEY BOTH BE REPLACED AS THE CABLE COULD HAVE BECOME HIGH RESISTANCE THEREBY CAUSING EXCESSIVE HEAT AT THE FUSE BOX. I HAD THE ALTERNATOR CABLE REPLACED WITH AN OEM PART AND THE FUSE BOX WITH AN AFTERMARKET PART. ON 10-9-13 WITH 104K MILES WHILE DRIVING TO WORK AT 6AM IN THE MORNING, THE EXACT SAME SYMPTOMS WERE EXPERIENCED AGAIN. LUCKILY I WAS ON A SIDE ROAD AND WAS TOWED TO A DEALER WHICH SAID THAT ALL OEM PARTS SHOULD BE USED AND THAT THIS IS COMMON AS THEY HAD JUST REPLACED THE ALTERNATOR CABLE ON ANOTHER JETTA OF THE SAME GENERATION. I REQUESTED THE DEALER CHECK THE ENTIRE ELECTRICAL SYSTEM INCLUDING THE ALTERNATOR BECAUSE THE PARTS THAT WERE INSTALLED LAST YEAR SHOULD NOT GO BAD IN 1 YEAR, THE DEALER SAID THERE WAS NO OTHER ISSUE. I AM NOT THE ONLY ONE EXPERIENCING A MELTING FUSE BOX. AT THE LINKS BELOW ARE OTHERS WHO HAVE EXPERIENCED THE SAME THING, EVEN ACROSS OTHER VW MODELS. THERE SEEMS TO BE A SERIOUS PROBLEM OF MELTING OF FUSE BOXES WHICH CAN OCCUR AT ANY TIME THE VEHICLE IS IN OPERATION. (WITH PICTURES) HTTP://FORUMS.FOURTITUDE.COM/SHOWTHREAD.PHP?4562591 HTTP://FORUMS.VWVORTEX.COM/SHOWTHREAD.PHP?4682918-WHY-S-MY-FUSE-BOX-MELTING HTTP://NEWBEETLE.ORG/FORUMS/QUESTIONS-ISSUES-CONCERNS-PROBLEMS-NEW-BEETLE/28982-BATTERY-FUSE-BOX-MELTING-04-NEW-BEETLE.HTML HTTP://FORUMS.VWVORTEX.COM/SHOWTHREAD.PHP?4705261-BATTERY-LIGHT-FLICKERING-ON-ACCELERATION HTTP://FORUMS.VWVORTEX.COM/SHOWTHREAD.PHP?4829541-BURNT-BLACK-CABLE-FUSE-BOX-ON-TOP-OF-BATTERY. *TR