Would it be helpful to clean the contacts on the heater blower itself
including the ground?
Perhaps 15yrs of oxidation on the terminals may be causing some resistance.

doug

----- Original Message -----
From: "Tolga Morawski" <tolga@MAC.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Thursday, September 30, 2004 8:09 PM
Subject: Re: First cold day

> Yeah I've had that problem too...I had always assumed it was a wiring
> problem, short or some such, isolated to my van.  Gotta love VW for that
> German engineering...how's about a beefier switch?
>
> At any rate I eventually got so aggravated with all my melted switches
> (it seemed to get worse, ie melt quicker as time went on but it may be my
> imagination) that I modified the contacts (pulled the terminal for "Hi")
> to eliminate that position, effectively giving the switch 2 off
> positions.  No more worrying that I'll forget it and wreck another switch.
>
> Take Care,
>    Tolga
>
> >Date:    Thu, 30 Sep 2004 07:55:26 -0700
> >From:    Malcolm Stebbins <mwstebbins@YAHOO.COM>
> >Subject: Re: First cold day
> >
> >too many 'its' in this sentence to know what you're talking about, but
> >yes, the fan switches melt
> >if left on HI for too long a time.  Design flaw.  M
> >
> >--- "Lastfogel, Darren" <dlastfogel@PLYFORMS.COM> wrote:
> >
> >> Today was the first cold morning that we had in Michigan and the first
cold
> >> day in the roachcoach and it heated up very warm, the fan switch was
> >> originally melted when I purchased it and it was also melted. Does
anyone
> >> else experience this problem.