[Main 9000 Bulletin Board | BBFAQ | Prev by Date | Next by Date | Post Followup ] Member Login / Signup - Members see fewer ads. - Latest Member Gallery Photos Da fix Like This Post: - Subscribe to Daily Digest for this Bulletin Board Posted by Ari [Email] (#2847) [Profile/Gallery] (more from Ari) on Thu, 26 Jul 2001 09:37:06 In Reply to: Headlight Relay, Michael O'Brien, Wed, 25 Jul 2001 10:53:12 Alert me when someone posts in this thread: Members do not see ads below this line. - Help Keep This Site Online - Signup

So you don't have to search for it-
You'll need a fine soldering iron. Pop the plastic case off. You'll see that there is a circuit board with some electronics and a relay mounted on it, and the board is attached to the relay lugs. Everything is held together with solder, and solder makes for excellent electrical connections, but is NOT a mechanical mounting method. Over time and vibration, the weight of the relay makes for hairline cracks in the solder pads holding the relay to the board, and the board to the base of the case.

If you look with a magnifying glass, you'll probably see some cracks at the edges of one or two large solder pads.

Touch up the solder on all the LARGE solder pads - the ones holding the relay down to the board, and the board to the lugs out the base. Just reflow the solder with just a touch of new solder. Leave the smaller solder pads, the one holding on the electrical components alone. Those rarely have problems, and unless you're very skilled with soldering small electrical components, you can easily cook them.


I'd stay away from a used headlight relay, because this is a common problem with all of them. What's to say that the used relay you buy doens't have the same problem? Or if it's working now, how much life is left?

THis solder fix has worked fine for me, and I've never had to fix a 'fixed' one yet.

Good luck!

• Headlight Relay, Michael O'Brien, Wed, 25 Jul 2001 10:53:12
  • Da fix, Ari , Thu, 26 Jul 2001 09:37:06 <-- Viewing This Message
  • Your chance to be proud and $ave: Open the large relay, I am, Daren, Wed, 25 Jul 2001 13:09:38
    • Ari had a detailed description of this repair a few months ago, bryan , Wed, 25 Jul 2001 13:20:15
  • Try the sponsoring vendors, Erwin Timmers, Wed, 25 Jul 2001 12:10:35
  • I wouldn't jump at the conclusion so quickly, David L, Wed, 25 Jul 2001 12:09:46
  • Re: buying USED electrical items is a BAD idea, n/m, Phil, Wed, 25 Jul 2001 11:02:16

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