NHTSA Complaint #11455949 — 2016 KIA SOUL

The rotating contactor switch for the heat/air conditioning fan on the dashboard appears to get very hot on the internal side. This resulted in discoloration of the plugs on the back side of the control panel, and melting of the contactor housing within the control box. No modifications have been made to this system to my knowledge, and no fuses were burned out prior to the dial failing, due to the melting plastic creating an air gap between the contactor terminals. Half of the plastic on the housing appears to be a heat resistant glass reinforced polyamide, and the (melted) half appears to be made of standard ABS plastic. This implies engineering expected this component to get hot, but still cut costs irresponsibly by using cheaper ABS in hope that the other half of this component would not get hot enough to melt (or potentially catch fire, had the plastic not melted away in a fashion that simply disconnected the contactors). I believe this case is not unique, as failures of this component appear common online. However I believe the true cause of failure (and potential risk of fire from the heat) has not yet been identified due to this contactor being located within a sealed control board assembly.