Melting Plastic Smell When Using MAX Heat

[Glen Baker LLC]

Twice about 2 weeks apart.
I noticed a melting plastic smell from my heater when using Max Heat.
2023 Hybrid XLT Lux pack. 16,000 miles
1. First start of the day.
2. Ambient temperature 30°-35° F Dry
3. Max Heat selected +85°F
4. Foot position selected, Fan speed 6
After 5-10 min. Driving I started to smell plastic burning. (chlorine scent)
7. The smell went away when I turned the temp down to 80°F or less.
8. A week or two later I used Max heat again and the smell was there until I lowered the temperature.
9. The Cabin air filter was changed in between the two occurrences.

Guess I will be getting in touch with the dealer or sending this to the Ford rep. here on the forum.

In the meantime I'm looking through these threads
https://www.mavericktruckclub.com/forum/threads/hybrid-heater-performance.6932/page-4#post-165839

https://www.mavericktruckclub.com/forum/threads/first-time-using-heat-bad-smell.19828/

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[Glen Baker LLC]

This was the configuration I had.
When the scent of melting plastic was present.

 

[Ozarkbeard]

In the Hybrid, when you turn the heater temp to MAX, it engages the supplemental resistance heat. If you've never used it before, there may be some odor until it burns off whatever is on the heat strip.

If you've used MAX heat before, check your cabin air filter and replace if needed.

 

[Glen Baker LLC]

In the Hybrid, when you turn the heater temp to MAX, it engages the supplemental resistance heat. If you've never used it before, there may be some odor until it burns off whatever is on the heat strip.

If you've used MAX heat before, check your cabin air filter and replace if needed.

Thank You for the reply and suggestions.
I'm somewhat familiar with
The electric booster heater. It is a heater element made up of ceramic resistors that is mounted in the climate control housing. It directly heats the airflow.
The smell still emanated even after the second time I used it about a week apart maybe 2 weeks.
I thought it would have burned any smell off the first time.

In between the two occurrences. I changed the filter. Well I had the area part I took the opportunity to take some pictures that I had posted.

Thank you again I'll keep searching

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