I had a similar problem on my 2000 Navigator (it's for sale, BTW).
Finally figured out that the switch was capable of sticking "on the edge" and it would sit there and make/break contact.
Replaced while still under warranty.
Steve
98 Contour SE Sport 2.5 Duratec ATX The wifey's car
89 Taurus SHO - 246K miles
94 SHO ATX - 190K
1997 F-150 5.4L ATX - The Workhorse 150K.
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