NHTSA Complaint #769664 — 1992 FORD AEROSTAR EXTERIOR LIGHTING:HEADLIGHTS

Complaint Details

ODI Number	769664
Vehicle	1992 FORD AEROSTAR
Component	EXTERIOR LIGHTING:HEADLIGHTS
Date of Incident	September 29, 1998
Date Filed	November 15, 2002
Mileage	N/A miles
Crash	No
Fire	No
Injuries	0
Deaths	0
Vehicle Towed	Yes
State	ND

Consumer Description

WHILE DRIVING AT HIGHWAY SPEEDS AT NIGHT, HEADLIGHT SWITCH (F49Z-11654-A), WITH AUTOLAMP OPTION, FAILED AND HEADLIGHTS STARTED FLASHING OFF AND ON THEN GOING OUT COMPLETELY. THIS HAS OCCURRED THREE TIMES, 9/98 AT 93,000 MILES (SWITCH REPLACED), 8/01 AT 145,000 MILES (NEW SWITCH AND BLOCK INSTALLED W/OLD WIRING) AND 10/02 AT 160,000 MILES (NEW SWITCH AND BLOCK W/NEW WIRING INSTALLED). VEHICLE NORMALLY DRIVEN WITH HEADLIGHTS ON FOR SAFETY SO USEAGE TIME ON SWITCH IS EXTENSIVE. EACH TIME LIGHTS WENT OUT, THE HEADLIGHT SWITCH CONTACTS, TERMINALS AND WIRE TERMINAL CONNECTORS HAD OVERHEATED AND DISCOLORED. THE OVERHEATING MELTED AND DISTORTED THE PLASTIC SWITCH CASE AND TERMINAL BLOCK (D3TZ-11A648-A), ALLOWING OR FORCING TERMINALS TO DISTORT OR MOVE. BOTH OF THE BATTERY POWER TO MAIN LIGHT SWITCH TERMINALS, A & B AND THE MAIN LIGHT SWITCH TO DIMMER SWITCH TERMINAL, WERE THE ONLY ONES OVERHEATED. DT

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