Horn Assembly problems of the 2002 Volkswagen Passat

My 2002 vw Passat initially blew the #5 fuse which controls the a/c, steering wheel items (horn, volume control, etc. ) and items on the driver side sun visor. The fuse was replaced and subsequently I experienced smoking in the area of the sun visor. Removing the visor, I noticed frayed wiring and burnt wiring insulation. In addition there was sparking inside the roof area. I took the car to the dealer and they cut the frayed wire and taped it up, with a more complete repair to come in a couple of days. Driving the car home later that day the car started smoking again with the addition of crackling sounds. I had the car towed to the dealer that evening. The dealer is now looking at the wiring and has found at least one wire leading from the visor area all the way down to the fuse box which is bare because it's insulation has been burned off. The fuse that should have blown was melted into the fuse box. The burned wire has also burned off insulation on other wires which were touching the damaged wire. The dealer is trying to track down all the wires that may have been damaged. Current cost is approximately $2400 with Volkswagen agreeing to pick up $900 of the cost. Based on internet research, there have been other reports of frayed wiring in the visor area of the 2002 Passat. I have numerous postings by people who have blown the fuse and had their visors replaced. Others have pulled down the visor and taped up the frayed wiring in their visor. I believe this to be a design or manufacturing flaw and I believe that my visor wiring has been fraying for some time prior to the catastrophic failure.

Horn quit working.

Following heavy rains on 29 sept 2004 vehicle windows/locks were inoperable. Fuse blown. Replaced fuse, horn would not stop and windows still inoperable. Unable to turn off vehicle lights. New fuse blown. Towed Passat via vw roadside to dealer. Told fri 1 oct 2004 that there was standing water in car and comfort module would need replacement. Due to water, the carpet & module would not be covered under warranty. Est 1500. 00 in parts pre-labor. As the windows were not operable, we do not know how this water damage occurred. Vw claims to due debris in sunroof, drains clogged and flooded floor. Unacceptable as car was detailed 2. 5 wks prior and is washed every week. Asked to see debris, they could not provide anything. We feel this may be due to the window surround trim that continually came loose/fell off or prior concealed damage (certified used vehicle). Note that seats/headliner were completely dry. We did not notice wet carpets as only the rear was wet. Car smelled awful @ vw on Friday 1 oct as it is turning into a mold pit. Filed geico insurance claim-waiting on adjuster.

Can't get any parts of car warranted since I had filed a complaint with bbb. Including no horn, both headlights went out with in 4 days of each other, the engine has erratic shift points especially when cold. The problem is vw says not to let the engine warm up but my engine oil heater is broken. Takes about 10 minutes at freeway speed to warm up. And the supposed abs are not really abs brakes when emergency braking from 75 mph. And many little interior mechanical issues.