Often the melted switch is caused by the blower motor. The motor
bushings get dirty and dry out and the amperage goes up and melts the
switch. Take a look at this tread.

http://gerry.vanagon.com/cgi-bin/wa.exe?A2=ind0602C&L=vanagon&D=0&P=21021

After taking my motor out I use electric motor oil on the bushings to
get it moving again and then connected it to a 10 amp battery charger.
At first it was drawing around 8 amps and I would stop it often to add
more oil. I think it was down to about 4 amps after running 48 hours or
so. Has been working fine for over 4 years now.

Bus Depot has the switch for $5.82
http://busdepot.com/details.jsp?partnumber=171959511

Steve

On 27-Dec-09 17:50 David Cohen sent the following:
> Hi,
>   I have a 1990 Vanagon GL and just recently the knob for the front  heater
> stuck in the number 3 position.  It will turn off and back on to  number 3
> fan position if I wiggle the knob but will not move back to number 2, 1  or
> off position.  Also the knob pulls out of the switch but doesn't look
> broken.  Any ideas how to fix this?  I need my heater to work  correctly in these
> cold weather days.
>
> Thanks,
> David
>