I replaced 2 ignition switches, the third one is broken again.

For some reason they 'melt' around the starter contact. It is always black there with burnt plastic. The rest of the switch is fine; Maybe too much current flowing through, but I have a stock/rebuilt starter, nothing special there.


Any ideas?

 

Have you replaced the plug pig tail that is burnt? If the terminal makes poor contact, it will only create more heat. You can get ACDelco part #PT289 to replace it.

 

that's a good idea; do you know how far does the connector go on the other end? (I don't feel like ripping half of the dash out to change it )

 

The plug would come with just a short length of wire on it and you would have to cut off your old plug and splice the new one on. IMHO, solder and heat shrink tubing would be best.