DIY
Main Relay Repair
Required Tool list
Solder, Soldering devise, screw driver
Inspection
Step 1
take apart the relay.
start by inserting the screw driver into the crack in the housing
then force the screw driver outward to push the plastic up
repeat step on otherside.
sometimes u'll find the upper plastic piece will come off, sometimes the whole hoard will pull out with it. either case, pull the board out.
Step 2
inspection
take a close look at the contacts on the backside. look for any cracks or breaks in the soldering.
Here are some good examples:
Normal good condition...
here u can see the soldering doesn't have any cracks.
Bad condition...
here we can see the soldering is all cracked, on all sides of the contact. this relay isn't going to start a car in this condition
Damaged but still works...
here we can see that 1 is perfect, but the 2nd contact isn't. it still has a good connection, but one side of it has a crack in it. This really will work like normal, for now.
Soldering
Step 1
First you want to make sure your tip is in good working order, here are some examples.
you can see the 2 on the right are piss poor, they wont get hot enough and wont solder too well. the one on the left is new, you can see its shinny and the tip is not damaged or worn, its ideal for use.
Step 2
Make sure to get the tip hot, it'll take a few minutes. You can test to see if its hot enough but touching the solder to the tip and if it start to melt right away, its good, don't do this too long.
Now that the tip is hot, place the tip to the connection on the relay, and the new solder to it as well, like so
you'll see the existing solder start to melt, quickly touch the tip with the new solder and melt it over the connection.
Do this until you get a nice round lookin thing
now that looks like its going to have a good connection!
Reassembly
Step 1
If the plastic part came off the board, snap it back into place.
Step 2
Insert the board into the housing, there is grove for the board to slide into
Push the board and plastic thing back into place, first press it in by the connector, then press the rest of the thing back place.
Job complete
Test the relay by putting it your car and starting it up!