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Headlamp Relay - over heating 700

posted by  S70780 on  Fri Sep 24 16:26 CST 2004
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I am having a problem with my headlamp relay. It gets extremely hot, hot enough to basically almost burn your hand when you touch it. Sometimes, it creates a smell of burning. Also, sometimes when i turn my headlights on, they do not work, I have to play around with the relay. Any ideas on the problem? I have tried installing a new relay, but it does not sit right, and is not really making contact, therefore does not work?








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    Headlamp Relay - over heating 700

    posted by  ndesouza on  Fri Sep 24 17:41 CST 2004
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    last visit: Sun Mar 18 15:14 CST 2012
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    'It does not sit right' is possibly the problem. Check to see if the terminals that the relay plugs into are clean, and the heat has not caused a hole to be burned into the plastic relay-socket around the loose terminals. This ends up pushing the terminal down when you try to plug the relay in.

    I've had this happen to most of my relay-sockets. To fix it I picked up sockets from a junkyard and swapped them with mine.

    You can use a small flat watch-screwdriver to push the terminal locking-tab and get the terminals off. Its difficult to explain, but if you have a good look at a terminal you will understand what I mean.

    You will need to pull out the relay board all the way (after removing the cigarette-lighter / receptacle box) to check these sockets.

    Noel








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      Headlamp Relay - over heating 700

      posted by  S70780 on  Sat Sep 25 04:06 CST 2004
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      hey Noel,

      thanks for responding. I am going to check it out. I think the terminal is gone b/c of the fact that the relay moves around very easily. I tried installing a brand new relay, and it won't really go into the terminal at all, just on one side of it. I'm a little worried b/c I already spend over $1,000 last year to get the entire car re-wired b/c I was having electrical problems. Also, I ran higher wattage bulbs( which I did not realize til a few months ago) so that may have led to the terminal being worn out and burned?








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        Headlamp Relay - over heating 700

        posted by  ndesouza on  Sat Sep 25 08:27 CST 2004
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        last visit: Sun Mar 18 15:14 CST 2012
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        I forgot to mention that the terminal-sockets can be removed by pressing the 2 clips on either side of the socket.

        Until you get new sockets you could temporarily fix your problem by doing the following.

        - Pull out the relay board
        - Pull off the problem relay
        - Identify the loose terminals and the corresponding wires below the board
        - Push each loose terminal all the way up so it pops out above the relay board. If you cant, make sure you hold the wire firm when the relay is plugged in so it dosn't get pushed down
        - Plug these loose terminals into the relay first by hand
        - Plug the relay in while holding the other wires firm so the terminals dont get pushed down.

        Noel







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