Burning smell when lights are on

Make sure your contact in the socket is touching the bulb.

All is well with your fan. Light bulbs sometimes will blow with a surge of power. This happens to everyone. If you feel uncomfortable with the 60 watt go for 40 watt. It will be less bright however. No need to worry about the fixture catching on fire

Sounds like you are drawing too many amps through the circuit. Window defoggers draw a lot of power which could be the culprit and it tied into the circuit. Unless you are good with schematics and vehicle wiring, it's difficult to narrow it down to what it could be.

blower resistor is common to burn causeing smell. check with dealer, there may be a campain on this problem. if not. replace resistor and harness (pig tail) and blower motor..

There is a short in the circuitry. Replace it or have a professional repair it.

Headlight switch and wiring harness is burnt/burning.

I think you have already figured out what the problem most likely is; 60 watt bulbs. Down-size the wattage or install 'energy saver' bulbs if they will fit the application. Instead of counting on these units for extra lighting, perhaps think about Track lighting to fill in those ares that need more but subtle light.
Good luck. :)

If it is burning and arcing at the antenna, it is probably arcing in the wave guide area. Probably will have to replace unit. I have had some success by removing the antenna, sanding and repainting the burnt areas of the cavity and sanding off any burnt marks on the antenna. Need to look at top of mag to see if also arcing there too.

.. any heat element like bulb must be installed exactly and that means its wattage, voltage and physical characteristics.. and also make sure that you have replaced Fan blowers and making it sure that it runs properly when the unit is on. as it was said also make sure that you do check the light that travels thru lenses and filters that is not block by dirt, cables or any other foreign materials.

The controller needs to be repaired. We regularly repair these control board assemblies for only $32.50 nationwide, and that's much cheaper than replacing the board. For safety, disassembly and other info see http://tinyurl.com/yzjozk