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relay cold solder joint cracks are often deeper than they seem. Usually you really need a nice hot gun/iron to re-flow the solder to completely penetrate the cracked joint.
i recently had to re-re-solder my hazard relay because joints re-cracked after I did it a few months back with a cheapie soldering iron.
Did you re-flow every terminal joint? Some of them serve more as a mechanical support to the relay than others.
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