Potter, Tom E wrote:
I just discovered another engineering problem with the Ford trucks: the
headlight switch connector melts. I say this is an engineering problem
because I have it on three trucks: a 1991 F-350, a 1992 F-250, and a
1995 F-250. Surely, by this time you would think Ford could have
corrected the problem. Definitely not a "better idea."
GM had a similar problem in the '70s and '80s: the high blower
connection would melt. They also never fixed it as far as I know.
You would think any jackleg mechanic (much less an engineer) would know
that running 25-30 amps through a small slip-on connection is inviting
disaster.
You would think. But the Germans aren't immune, either; VW did it for
years. Pretty much all VW models from the 80s are known for melting
blower switches -- they all used basically the same flawed part. The
problem was the switch was adequate (barely) when the blower was new and
the switch contacts were clean. As the blower aged, the current draw
went up. Add in resistance from a dirty switch contact and the switch
would melt down on high speed. The headlight switches and ignition
switches liked to burn up, too.
