NHTSA Complaint #11443862 — 2016 SUBARU CROSSTREK

I have had three occurrences with my vehicle where I discovered a dangerous situation in the manual heater and air conditioner control module connector that resulted in the module connector and the wiring harness connector both becoming scorched and melted due to excessive heat. I believe that this is probably occurring due to high electrical current at the connector. In all occurrences, the first symptoms of the problem are intermittent blower fan speed followed by the fan speed knob becoming melted into a fixed position. The first occurrence was in February 2021 and the damaged control module (part number 72311FJ500) and the pigtail connector were replaced by a trained auto body tech. The second occurrence was in August 2021 and I took the vehicle to the Subaru dealership given it was a repeat occurrence and because we were concerned it might be a problem that could impact other vehicles. The service department at Subaru kept the vehicle for 2 weeks to diagnose the problem and eventually recommended we replace the vehicle's main wiring harness as well as again replace the damaged heater and air conditioning control module. We authorized the required repairs. The issue has now occurred for a third time and I will be taking the vehicle to Subaru again. I will be asking the service department to contact the manufacturer about this safety issue. I believe the primary risk to safety the potential of a fire in the vehicle in the right circumstances due to excessive current at the connector of the module. There is a secondary but less acute risk that the heater becomes inoperable during the winter and puts occupants at risk which is the situation we are facing as we travel frequently in rural areas.