Re: 01 Aero highbeams only work sometimes? - Saab 9-5 Bulletin Board - Saabnet.com
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Re: 01 Aero highbeams only work sometimes?
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Posted by Bicycler [Email] (more from Bicycler) on Thu, 22 Oct 2009 02:02:58 Share Post by Email
In Reply to: Re: 01 Aero highbeams only work sometimes?, SWEDECAR [Profile/Gallery] , Wed, 21 Oct 2009 08:46:48
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The orange "relay" is the headlamp filament current detector.
Was in the 9000 anyway.

Prise it open & look for the cracked solder joints.
Solder joints do not survive mechanical stress, thermal cycling & bad alloy choice, wrong base metal plating etc.

The best rework fix is to wick of the existing solder.
Maybe tack one joint to maintain part alignment.
Resolder with eutectic lead solder preferably Sn62 (Sn62%Pb36%Ag2%).
Sometimes called LMP low melting point (178°C vs 182°C for Sn63).

More solder is better than less but do not bridge/short across the edge connection.
The Sn62 alloy is the best for almost all applications especially thermal cycling, stress creep fatigue inter-metallics etc.
Some lead free solder alloys can be okay but are harder to solder well & are harder to inspect.

Wicking off the old solder stops the existing alloy compromising the new alloy chemistry & removes contamination that will be in the crack from arcing current & inter-metallics that will not dissolve.

Fixed this way, it will outlast the car !
Made this way, it probably never fail .
B.


posted by 203.184.17...

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