Ignition Fuse Problem

2 Weeks ago my ignition switch fuse wire melted along with the 25a fuse. I replaced the wire with a smaller fuse 15a like autozone told me. Driving down the highway today my overdrive was kicking on and off. I looked at the fuse and wire and it has begun to melt again and the fuse plastic is turning brown. I know it will melt beyond use again but what is causing this? I had a trusted mechanic replace the ignition when it went out about 2 months ago. Whould they have replaced the fuse? Could the wire and fuse they put in be completely wrong? SHould it be a bigger fuse that just snaps in without wire?

Thanks

...a trusted mechanic replace the ignition ...

- Wire(s) heat(s) when overloaded (some odd cases when old/rotten). Overload here means a addon component with Amps rating not designed for this system.
- Connectors /fuses also warm from bad contact and/or oxidation.
- A related issue could be with your gearbox, control voltage drop due to transition losses; read and clean... http://www.cardomain.com/ride/748507/14 ...&page15

Generally, keep fuses same, add thicker wire. The thicker it is, the more it can carry load (compare to starter wire:) ...btw, its NOT possible to add too thick wire.

I cannot say what was done ("...mechanic replace the ignition"), but symptoms point to issues 2mths ago, 2weeks ago... Generally now too thin wiring. Maybe there were non original components installed, overloading the system. Whatever the reason, current wires are too thin to carry the load (add new, thicker, and/or second wire parallel).

Dont drive until this problem is solved, its real fire hazard.

Seek other points where harness could be melted, rotten, repaired (taped), addon rotten jump connectors...

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