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Headlight relay Posted by Ari [Email] ![]() ![]() In Reply to: Bright Lights, 96Areo, Tue, 31 Oct 2006 22:05:49 Members do not see ads below this line. - Help Keep This Site Online - Signup |
That is the starting failure mode of the headlight relay. Look specifically for the relay marked "headlight" in the relay box in the engine compartment. Not the monitor.
You can replace the relay, or if you're cheap, fix it. The problem is that due to the heat and vibration inside the engine compartment, some of the solder joints inside the relay fail. They develop little micro-cracks, and these cause intermittent connections. If you have access to a soldering iron, repair is simple. Remove the case by prying back the tabs on the bottom a little. Slide the case off, and you'll see a circuit board with the actual relay on it, along with other circuitry. The solder is both an electrical connection, and it also holds the relay in place. Solder isn't designed for this, so the big weight of the relay stresses the joint.
With the soldering iron and A LITTLE fresh solder, re-flow ONLY the large solder pads. They are the only ones that crack, and a little extra heat won't hurt them. The smaller pads go to sensitive electronics, and too much heat can damage them. And the smaller pads don't fail. With a magnifying glass, you may even be able to see the cracks in the solder pads where the leads come through.
This usually fixes the relay for another decade or so. And if you really mess it up, get a new one. But trying to fix it is cheaper.
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