This 1996 Dodge Intrepid came in with the complaint that then blower motor and the power windows stopped working at the same time. Having been down this road before I first wanted to get a look at the ignition switch. I started by removing the screw that holds the tilt lever in place.
Next I removed the screws attaching the lower cover to the steering column assembly and pull the cover off of the column.
Then I lifted the top cover from the steering column.
I removed the two attaching screws for the ignition switch.
After removing the switch and separating the harness connector from the switch this is what I found. Notice the discoloration on the top right terminal in the following picture.
Along with the melted plastic and discolored terminal in the corresponding terminal at th bottom right of the next picture.
I checked with The Electric Connection and the Dodge dealership as well and found that a repair connector is not available. I removed the burnt terminal from the connector body and realized it was the same as the terminals used in the part #4200 from The Electric Connection so I removed a wire from the new connector that was the correct gauge size.
Spliced it into the the old ignition switch connector. I used a pair of hose pinch off pliers to grab the harness and keep it pulled out far enough to be able to work.
Pulled the expandable loom back into place and secured with electrical tape.
Installed a new ignition switch and tested the systems, all working as designed again. The lesson of all of this is sometimes you have to know how components are manufactured and how manufacturers use individual components (think outside the box). If you do not know, ask someone that does.
Thanks for the guidelines, that was my exact problem too, very common problem, all windows stop and blower motor stops as well as the turn signal and airbag light coming on. but the dodge dealers pretend like they don’t know what your talking about when they know its a recall issue, and it actually is a recall on it, very easy job i removed and replaced mine in a matter of 10 minutes and 28 bucks for the part at the wreckers thanks to Sparky’s the pics took the guess work out on which switch it was, and i was lucky enough the the wire hadn’t overheated yet so i didn’t have to splice in a new wire, thanks again
I read your repair proc and I installed a new ignation switch and the a/c blower &electric windows, and the a/c button light and air bag light now shuts off. thanks, everything is now good to go Tom
ducaose
Thank you for this post, I was able to catch the problem before the plastic metled. In addition, I replaced the turn signal connecting box and my turn signals work again. Really appreaciated your insight, please let me know if you work on the car again.
Awesome! Thank you!