NHTSA Complaint #725789 — 1995 MERCURY SABLE

I HAD BEEN NOTICING A STRANGE BURNING SMELL IN THE CAR FOR SOME TIME - BUT COULDN'T PLACE ITS SOURCE. I FOUND THE SMELL GETTING STRONGER OVER TIME, AND STRONGER WHEN THE HEADLIGHTS WERE ON. THEN I NOTICED THAT THE DASH AREA SURROUNDING THE HEADLIGHT SWITCH WAS WARM TO THE TOUCH. I PULLED OFF THE HEADLIGHT SWITCH KNOB, AND THE SWITCH SHAFT WAS BURNING - TOO HOT TO TOUCH. I OBTAINED A NEW HEADLIGHT SWITCH AND PROCEEDED TO DISSAEMBLE THE DASH. I FOUND THE BACK END (PLASTIC CONNECTOR RECEPTABLE BODY) OF THE SWITCH TOTALLY MELTED, AND SOME OF THE WIRES HAD THEIR INSULATION MELTED CLEAR OFF, DOWN TO BARE COPPER. LUCKILY NONE OF THE WIRES WERE TOUCHING IN THE BARE AREAS. THE MALE END OF THE HARNESS (THAT PLUGS INTO THE SWITCH) WAS MELTED INTO THE SWITCH BODY. I HAD TO BUY A NEW REPLACEMENT CONNECTOR, SPLICE IT IN AND MAKE UP SOME NEW WIRES, AND THEN INSTALL THE NEW SWITCH. THE AUTO PARTS STORES SAY THAT ALTHOUGH FORD DOESN'T HAVE THE CONNECTOR + PIGTAIL ASSEMBLY AVAILABLE AS A DEALER ITEM, IT IS AN AFTERMARKET ITEM SINCE "THEY BURN UP SO OFTEN." HAD I NOT INTERVENED WHEN I DID, I COULD HAVE HAD A SEVERE IN-DASH FIRE, PLUS LOST MY LIGHTS AT NIGHT. MY LIGHTS NEVER STOPPED WORKING, ALTHOUGH THE BURNING SMELL WAS EVIDENT. MERCURY CUSTOMER ASSISTANCE ADVISED NO PRIOR REPORTS OF THIS TYPE.*AK