NHTSA Complaint #10744030 — 2003 FORD EXCURSION

AT NIGHT, IN FOG, IN DRIVEWAY, I TURNED ON HIGH BEAMS, DEFROSTERS, WIPERS AND LOWERED DRIVER WINDOW. A MAJOR SILVER ELECTRICAL CIRCUIT IN THE FUSE BREAKER BOX OVERHEATED MELTED AND POPPED. FORD'S INCOMPETENT ELECTRICAL ENGINEER'S DESIGN CAUSES CIRCUIT BOARD SILVER CIRCUITRY IN FUSE BOX TO MELT, WHILE NO CIRCUIT BREAKERS MELT/WORK. THE CIRCUIT THAT MELTED ALSO CAUSES VEHICLE TO LOSE USE OF INDICATORS AND GAUGES IN THE DASH GAUGE PANEL, THE ALTERNATOR ALSO FAILS TO WORK AND VEHICLE DIES WITHIN A DAY, WITH NO WARNING, WHILE DRIVING, DUE TO TOTALLY DEAD BATTERY. FORD HAS AT LEAST THREE DIFFERENT VERSIONS OF FUSE BOXES FOR THE 2003 EXCURSION XLT 5.4L. FORD HAS NO REPLACEMENT FUSE BOXES TO SELL. PROBLEM IS SO COMMON ON THE INTERNET, I LUCKILY LOCATED THE LAST USED FUSE BOX IN THE COUNTRY, 1000 MILES AWAY FROM CA. FORD'S ONLY SOLUTION WAS A NEW FUSE BOX FOR A NEWER F150 COSTING $750 AND REQUIRING HUNDREDS OF MORE DOLLARS TO MODIFY IT FOR AN F250/F350/EXCURSION. THE MELTING FUSE BOX HAPPENED TWICE IN ONE YEAR AT $500 PER FAILURE. TECHNICIAN HAD TO PUT IN AN EXTERNAL BYPASS WIRE WITH ITS OWN EXTERNAL CIRCUIT BREAKER. NO MORE MELTDOWNS IN 2.5 YEARS. INCOMPETENT FORD ELECTRICAL ENGINEERS.