Cool Fan Relay socket Melting

[smcguiga]

I just picked up a few relays from Dave, among them is the cooling fan relay. I decided to change out my front fans with the newer ones and install the new relay. Well upon finishing the fan swap and moving to change out the relay I see this... :what_the:

44460

44461

As you can see, I installed the new relay but the wiring is still really hot to the touch when running...as well as the circuit breaker connection. I guess (hope) the old fans were the cause, but should I be looking for a loose connection somewhere? If so, where??? Also, where I can get a new plastic socket? :) The fourth relay socket down shows some melting as well. I'm hoping this was caused a while back when my cabin fan was failing and finally seized.

--Steven

[Bitsyncmaster]

Those OEM fans just can not be trusted. I checked one set of them that would draw a little over 14 each but started a fire with fan fail fused jumpers. So they must have drawn more current than 14 amps each but when I test them it's no guarantee they will stay at that current.

[smcguiga]

My concern is even though I have everything changed out, the relay socket and circuit breaker are still very hot to the touch. I'm just looking for a "what is normal" now that I have these changed out. If others don't see that these are really hot then I guess I need to look at re-doing some connections, re-crimp new ends, etc.

Anyone have a suggestion on the best source for relay receptacles/sockets ?

[81dmc]

I don't know, but that relay block definitely does not look stock! That can be identified due to the missing factory wiring and factory multi-colored connector blocks. If I were you, I would first check the wiring using a schematic, then move on to the fans. There is always the possibility of a short with mods using improper wire sizes (should be 10-12 gauge).

If you need a new block, I have a couple originals extra since I'm installing a standalone fan controller, custom sensors, custom coil wiring, etc.

[Bitsyncmaster]

It does look like your relay sockets have been replaced with some non OEM type. I think someone had found a source for the OEM black color sockets. I also have a few I removed from my car if you don't find them but you would need to replace all of them probably to get them to mount together.

[BABIS]

I think someone had found a source for the OEM black color sockets.

http://www.ebay.co.uk/itm/Black-Relay-Base-Holder-and-Mount-5-Terminals-Suitable-for-4-5-Pin-Relays-/140938481502?hash=item20d0968f5e:g:t10AAOSwofxUded Q

In my car I've added 3 relay bases next to the original ones ;)

[David T]

Once the sockets melt you have overheated the wire connectors and they lose their spring tension and no longer make good contact. The surface also oxidizes, again, making a bad connection. All wire connectors that show signs of heat damage must be replaced. I see a red wire cut and just hanging there, it appears there were some modifications done.

[smcguiga]

Yeah it looks like the relay sockets were all replaced and the wires from the sockets are a gauge smaller than the harness wires they are soldered to. I have replaced the one wire for the meted one on the cooling fan relay with a proper gauge wire and so far it doesn't appear to heat up. I replaced the end on the circuit breaker but it is still getting pretty hot. Both of those get hot. But those wires all look stock.


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[Bitsyncmaster]

Yeah it looks like the relay sockets were all replaced and the wires from the sockets are a gauge smaller than the harness wires they are soldered to. I have replaced the one wire for the meted one on the cooling fan relay with a proper gauge wire and so far it doesn't appear to heat up. I replaced the end on the circuit breaker but it is still getting pretty hot. Both of those get hot. But those wires all look stock.


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Fuses and circuit breakers produce a lot of heat when they are passing current close to the rating.

[Ron]

...wires from the sockets are a gauge smaller than the harness wires they are soldered to.That probably has a lot to do with it. The terminal ends will be of lower gauge/quality too...
You can buy heavy duty terminal ends with the release tab. Changing them (and smaller wires) out is relatively easy.
Silver solder them after crimping...

[Farrar]

I think someone had found a source for the OEM black color sockets.

I used these: http://www.sherco-auto.com/interconnecting-relay-socket-w-mounting-hole-housing-only.html

[Farrar]

Silver solder them after crimping...

Agreed. I also used heatshrink to make the ends a little stiffer:
44523
44524
44525
etc.

[81dmc]

I used these: http://www.sherco-auto.com/interconnecting-relay-socket-w-mounting-hole-housing-only.html

Off topic, but have you found those with the large pinouts for 70-80a relays? I want to mount the accessory relays on the relay block.

[smcguiga]

I used these: http://www.sherco-auto.com/interconnecting-relay-socket-w-mounting-hole-housing-only.html

Awesome! I've only ever used a simple cheap crimp tool with insulated terminals. I'm looking for the non insulated ends (brass maybe?) and a good crimp tool and I guess I'll work on redoing everything. Why would someone use smaller wire??

I just took at 20 minute drive and then checked various points with a heat sensor. The relay socket is up to about 110 degrees and the circuit breakers are around 120-130 degrees.

[81dmc]

Why would someone use smaller wire??

Simple. Most 30-40a relay blocks are sold with only 16-14 gauge wire.

[Ron]

Off topic, but have you found those with the large pinouts for 70-80a relays?

https://www.amazon.com/HELLA-H84703001-Socket-Terminal-Relay/dp/B000VUEDRU

ebay too...

[81dmc]

https://www.amazon.com/HELLA-H84703001-Socket-Terminal-Relay/dp/B000VUEDRU

ebay too...

I already know those are available, but what about 70a, slide-on blocks stylized the same as our originals?

[Farrar]

Awesome! I've only ever used a simple cheap crimp tool with insulated terminals. I'm looking for the non insulated ends (brass maybe?)

Like these? http://www.sherco-auto.com/14-female-terminal-wlocking-tang-100-pack.html


I already know those are available, but what about 70a, slide-on blocks stylized the same as our originals?

Those I have not seen. Sorry. :\

[81dmc]

Like these? http://www.sherco-auto.com/14-female-terminal-wlocking-tang-100-pack.html



Remember, these connectors use a "special" crimp tool, but fortunately, they are easy to find on eBay.

Here is the link (http://www.ebay.com/itm/Molex-Style-Crimp-Tool-Wiring-Harness-Crimper-Crimping-Opening-Barrel-14-24-AWG-/111664869648?hash=item19ffbeb110:g:NeIAAOSwie5XS-lT) to the cheap one I have...

[BABIS]

I already know those are available, but what about 70a, slide-on blocks stylized the same as our originals?

I guess these should work http://3waycomponents.co.uk/Categories/Relay-Holders-and-Bases/High-Current-Relay-Holders/70-Amp-4-Pin-Power-Relay-Base-Holder-With-Mounting-Bracket-Kit

[Bitsyncmaster]

I guess these should work http://3waycomponents.co.uk/Categories/Relay-Holders-and-Bases/High-Current-Relay-Holders/70-Amp-4-Pin-Power-Relay-Base-Holder-With-Mounting-Bracket-Kit

Good find. Never would have thought anyone would make those with dovetails. But those dovetails my not fit the OEM sockets. I replaced my OEM sockets with newer sockets. The new sockets look like OEM but the dovetails are sized different.

[81dmc]

I guess these should work http://3waycomponents.co.uk/Categories/Relay-Holders-and-Bases/High-Current-Relay-Holders/70-Amp-4-Pin-Power-Relay-Base-Holder-With-Mounting-Bracket-Kit

Those are exactly what I'm looking for, thanks!

[81dmc]

Good find. Never would have thought anyone would make those with dovetails. But those dovetails my not fit the OEM sockets. I replaced my OEM sockets with newer sockets. The new sockets look like OEM but the dovetails are sized different.

Well, if that happens, I'll make them fit...

[Farrar]

I guess these should work http://3waycomponents.co.uk/Categories/Relay-Holders-and-Bases/High-Current-Relay-Holders/70-Amp-4-Pin-Power-Relay-Base-Holder-With-Mounting-Bracket-Kit

Nice find!

[Bitsyncmaster]

Well, if that happens, I'll make them fit...

Just find the 30 amp sockets that mate with the 70 amp ones.

Some of those 70 amp pins will make it very hard to insert and remove the relay because of the high tension on the pins.