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relay meltdown, coupla questions post fix 700 1985

posted by  Rtilghman on  Mon Jun 10 08:49 CST 2002
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1985 745t

okay, so I'm driving a 3 hour trip and start to smell a little melting plastic. pull the ashtray and identify the source as some EXTREMELY hot headlight and foglight relays (burned myself on them), cut the lights to the minimum until I got home, and discovered gaping holes in the middle of the relay holders from the heat.

I just finished reconditioning both sets, replacing the holders, replacing the connectors, cleaning the relay contacts, etc. However, post assembly I've discovered that the foglight relay is now cooked. It's a 12 volt, Max 16 amp relay. I'm a relay collector at the junkyards, but amazingly I lack this particular relay. However, I do have a J relay with the same set-up that's rated 12volts, 40 amps. I actually used this relay to confirm the old one is dead (worked perfectly).

Can I swap in the higher amp J relay permanently? Can I swap it in temporarily until I have a chance to get a new 16 amp relay? What will be the problems if I do? Will it draw/supply more current and blow my foglights? Will it heat up more and possibly cause damage or blow something else? One of the wires from the foglight relay bracket is wired to the number 3 fuse which has a 15 amp fuse in it currently. Will that fuse just blow immediately from the 40 amp relay? Can I replace the fuse with a 30 or 40 amp fuse and be fine?

Just don't have the electrical knowledge to know the answer to any of these questions (more of a fiddler). Any help is appreciated.

Thanks,
Rick






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