Troubleshooting A 3-Way Switch Setup That Keeps Melting Wires

Updated 06/05/2023 | Published 06/02/2023

Question:

2020 Continental Cargo 34foot Race Trailer w/bathroom. TXAM8534TTA4 Melting wire issue at the switch. This trailer is all factory stock no modifications have been made. The primary lighting in the trailer is 12v LED. The switch is an SPDT, as it has one at the rear entry ramp of the trailer and the main side entry. For some reason, the common wires going from the main switch to the second switch keep melting at the connectors. It did not blow a fuse but instead heated up the switch where it no longer works. What could be the cause? Whats the best way to troubleshoot this issue?

asked by: Daniel G

Expert Reply:

An LED light isn't going to pull much so it's odd that you'd melt the wires consistently unless those connection points are somehow touching bare metal in the wall and shorting out. I would start by first ensuring that these connection points are covered with some electrical tape to avoid metal on metal and then connect it to power to see if the issue persists. If so it's most likely an issue with the switches themselves. There could be an issue internally causing multiple contacts to touch that we just can't see and you'd need to just replace the switch with another like part # 37213835.

expert reply by: Kevin C