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No start, headlight relay?!? This is new to me.
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Posted by EricG (more from EricG) on Tue, 8 Nov 2005 12:47:44 Share Post by Email
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Anyone ever heard of a bad headlight relay preventing a 9k from starting?

My wife's '95 Aero has experienced intermittant headlight issues for over a year. I've seemingly cured them by simply pulling the relay and reseating. Yesterday she came out to her car and it was totally dead. The remote unlocking did not work, the radio needed a new code when she got power, and there was not even a click when she went to start the car. She got the company's security force to jump the car, and it showed normal battery voltage, ie the battery was not dead. When she got home, I put the charger on it and it indicated the battery was fine.

I decided to do the 'headlight relay resolder' cure oft spoken about on this board, since she had had a problem with the relay earlier in the day. She simply switched the lights off and on, and the normal function returned.

When I pulled the relay apart, I could find no obvious cracks in the solder. There were several "tracks" of what appeared to be melted solder across two or more circuts. I used contact cleaner and a pencil eraser to attemt to clean up these areas. Partially successful.

I also used an 8x magnifying loop to inspect all of the solder connections. Other than a couple of oxidized connections, and some minor separations from posts, I could not find any obvious problems. Nevertheless, I melted the suspisious solders in hopes that any cracks or separation would be repaired.

I then swapped the repaired relay into my '95CSE and gave the wife the CSE relay. Today, after a 1min stop, my CSE refused to start. I pulled the relay, started the car, and replaced the relay. No problem yet on restarts.

Before I drop $70 on a new relay, has anyone heard of this before?? Is it fixable? Very strange....

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