Join Date: Oct 2003
Bronco Info: 96 XL 5.0 E4OD, Man Xfer/Hubs
Inspect the switch carefully;
Switch Fires, Part Number SW-2103: "...Over the past two years, this office has experienced fires caused by another potential problem in Ford vehicles. The problem exists within the dimmer portion of the head light switch in Ford vehicles. The light switch involved is a Model SW-2103. These are the pull out type head light switches usually located in the lower left corner of the front dash of Ford vehicles. The head light portion of the switch has two pullout positions, the first for parking lights only, and fully out for head lights and parking lights. The shaft of this pull-out light switch can be turned clockwise and counterclockwise which activates a dimmer switch, lowering and raising the intensity of the lighting in the instrument panels respectively. Fully rotating the shaft counterclockwise past a notch activates the interior lights within the vehicles. The potential problem exists within the dimmer portion of this switch. The dimmer mechanism consists of a metallic resistive coil set inside a ceramic disc positioned over the shaft of the switch. The coil is exposed on its front side away from the passenger compartment. The front side of the coil passes across a contact permitting a current to flow through a certain portion of the coil when the switch is pulled our in its first or second positions. The greater amount of coil through which the current is permitted to pass (clockwise most position) creates the greatest resistance and therefore dims the dash lighting to its lowest intensity. The opposite position provides greatest intensity. Through our investigations, we have found that the coil can fail owing to wear and/or possible material defects or damage. A fractured coil can maneuver itself free of the ceramic disc permitting it to come in contact with the metal bracket which mounts and grounds the switch to the vehicle. When this occurs, a current can flow through a portion of the coil creating high temperatures melting the metal material of the coil and possibly igniting surrounding combustibles. This mechanism has been observed in three separate incidents by this office. Two of these resulted in a fire. The mechanism is precipitated by wear and/or defect in the coil mechanism. If the former is true, we expect there will be an increase in fires caused through this mechanism given an increase in service time. To this date the problem appears to be somewhat limited. However, this particular light switch has been utilized in numerous Ford vehicles. Therefore, a small increase in failure rate owing to age and wear could result in a significant increase in fire losses. The SW-2103 Light Switch Assembly discussed above is reportedly installed in the following Ford vehicles: 1986 -1997 F100, F150, F300; 1990-1994 Explorer; 1987-1994 Ranger; 1987-1990 Bronco II; 1992-1997 Aerostar..." Source: by waltersforensic.com
Miesk5 NOTE: a shop or PO could have installed this particular switch design in other model year Broncos, see the Ford info below in the Buyer's Guide Results by FORD: Part Number: SW2103 Description: Head light Switch, Manufacturer: Motorcraft. Years: 1990-1994 Applications: 535: 1992-1994 Bronco; 1990 Bronco II; 1990 E-150 Econoline; 1990 E-250; 1990 E-350; 1990 Escort; 1991-1994 Explorer; 1992-1994 F Super Duty; 1992-1994 F-150; 1992-1994 F-250; 1992-1994 F-350; 1990-1994 F53; 1990-1994 F59; 1990-1994 Ranger
My 96 and according to Ford,
1995 Broncos and most if not all F series from 95-97 use Headlight Switch SW-5053
I you find coil is issue for the burnt connector body & terminal(s); Write to Ford & NTSB
96 XL 5.0 E4OD, Man Xfer/Hubs
USN/DoD Planner (ret); See my partially recovered Bronco web site
...Will need to clean up dead links & add many more new links some day. Thanks to Mr. Schwim!
THANKS to ALL WHO SERVE!