The grey connectors that fit into the RSR are shot. The pins are all loose. Does any one know if these connectors can be had or do I just sleeve the individual wires/ terminal with shrink tubing and connect them ?

Here's a good fix for this problem. What you need is this part no. from Volvo: 3523813. The part is a female connector with insulation attached to about 5ft of wire (same gauge as RSR wires). Before you start carefully note the color code of the wires to the RSR and their terminal position. Cut the wires behind the grey connector, pull them out the front, clean out all the crumbled insulation,then put your new wires in from the front of the connector(cut wire end goes first, obviously). The connectors will seat perfectly in the old grey connector. You will need four of these for one RSR. The wires come in white only. You end up with a perfectly restored connector.

JayS..thanks..I actually saw that in the FAQs and thought it was part of a post from the UK as the price for each was in Pounds...so I never gave it a thought to query my local dealer. Anyways I did manage to "fix" things , the new relay arrived and I installed it. I got it from FCPGroton , German made , but it was a 30Amp as compared to the original 40A.. I am keeping the old one even though one of the terminal ( no 4 ) shifted due to excessive heat.

My 1990 had the same problem. I pulled the connector and cleared all of the rubber away. I left the hard plastic part so I would know where the wires go. Cleaned it all, applied a dielectric grease and have no problems. As we all know, these can give problems. I carry a spare.

Recently the AC aux fan would not shut off. One of the twin identical RSR was sticking.

Hawkeye

I posted some pics in gallery under 700 technical . I dont know hot to put them with the posts as yet . Sorry

I had the same exact no-start with wife's 89 740. I pulled out the crumbled rubber from the grey connector and individually inserted each round female connector onto the RSR (after marking each terminal with the color code of the matching wire with a red wax-pencil).Coated the terminals with di-electric grease. Worked great for several years,until I got the correct connector in great shape from a PNP.
I don't trust aftermarket connectors to be the same diameter as the Volvo OEM.
buena suerte!
el raidman

This is where I am at as well..the rubber had crumbled in the connector and I used a needle nose pliers to reconnect the terminations into the relay. Its been a couple years now and what I notice is that there is considerable amount of corrosion on one of the bigger gauge wires in one of the relays and I want to tend to that. Also is there a possible relation between the RSR and the fuel pump (in-tank , regina ) OR its circuitry . Couple months ago I had an intermittent fuel pump problem in that the car would crank but the pump would not run and I am now wondering if this corrosion could have have been the reason

I had a similiar problem on my son's 1988 744t. Those cars have a disconnect on that circuit that is fairly well hidden under the short brace off of the firewall towards the fender well. The plug is the same as the one down the line for the radio suppression relay.

The problem started as an occasional loss of power and progressed to a die in traffic no restart with a ride home on a rollback. Somehow over twenty years one of those connectors had worked loose.

The plug had broken down and simply pushing it into the companion male portion didn't make full insertion on all of the connectors.

As long as you are aware of the possibility of one or more of the connectors not being pushed on all the way you can deal with it by using something like needlenosed pliers to push each individual connector into place, but as was suggested I think the quickest way to address the problem is to find a good plug at a pick and pull.

Randy

Sorry. I was wrong. If the socket is still good, why not hit parts store for the round connectors(probably need female) and fix the connections.
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You can usually find them at any auto parts store.
Here's an example.

http://www.parts-express.com/pe/showdetl.cfm?Partnumber=330-075
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I think the radio suppression relay has four pins and they are round.

Randy

Come to think of it , I do believe the terminals were round ..I would have to double check..in any event might this be a dealer item ?

Correct; time for a trip to the pick-n-pull.

aleekat...thanks ..saw them at parts-exp web site ...however do you know for sure (100%)that these will fit into the RSRs?

100% sure they won't.

I'm not sure, but take the relay with you to a parts store. Mine yr doesn't have a RSR or I could check..
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