1998 Ford Contour Heater emitting horrible smell/smoke

1998 FORD CONTOUR
110,000 MILES • 4 CYL • FWD • AUTOMATIC
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CLIDDLE
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Recently had new battery and new spark plugs. About one week after new plugs started smelling a burning rubber/plastic smell coming from the heater vent. No lights are coming on on the dashboard. Last night the car filled with smoke, I shut the heater off and no more smoke or smell. Pulled car over to make sure there was not a fire under the hood which there was not. As long as heater is off there is no smell of burning rubber/plastic. Car has had no problems ever other than fuel filter needing replaced frequently instead of just maintenence.
Dec 24, 2007 at 9:42 AM
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MERLIN2021
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On the passenger side, remove the panel under the dash, they just pull out, check the condition of the connectors and the blower motor...You may need to replace the blower...
Dec 24, 2007 at 9:47 AM
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CLIDDLE
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Ok the blower motor was replaced and smoke continues to roll out from under dash area near the blower. An electrical wire broke off literally after it caught on fire first.
Dec 24, 2007 at 12:12 PM
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MERLIN2021
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This only happens whe the blower is turned on? You will have th check that burned wire back to it's source, make sure it isn;t touching metal. There is also a resistor mounted near the blower, is it a wire from that to the blower?
Dec 24, 2007 at 1:00 PM
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CLIDDLE
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Come to find out it was the "blower motor resistor switch" had shorted out causing arcs/fire to the wires, which is only sold by Ford, no autozone, napa or anywhere's. Had to tape off the wires till the part comes in. You were right on the money Merlin! Good Job!
Dec 24, 2007 at 8:19 PM
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MERLIN2021
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Maybe the local junkyard might have one...Thanks!
Dec 25, 2007 at 7:44 AM
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