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Old 08-19-06, 01:56 AM   #1 (permalink)
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Fixed Main Relay & Pictures

My car finally refused to start in a hot day so I took out the main relay, find the cracked solder joint & fixed it with a solder iron. My car is starting reliably in a hot day again.

1. Main Relay location in my '91 Coupe. Very easy to find with the kick panel removed on the driver side:



2. This is how the Main Relay looks when it is out:



3. This is how the side looks:



4. Find the cracked solder joint on the circuit board:



5. Zoom in to the cracked solder joint (round crack):



6. I used a solder iron to reflow the solder (with new solder added)

The whole job is quite easy to do if you can solder a wire.

The following are the links to some very informative site about Honda Main Relay repair:

http://www.marklamond.co.uk/tech-hon...main-relay.htm
http://techauto.tripod.com/mainrelay.htm

-Tat
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Old 08-19-06, 09:26 AM   #2 (permalink)
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Did mine yesterday as well. I only found one or two that had bad joints, but I went ahead and did every joint on the relay. Very easy to do.
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Old 08-19-06, 10:35 AM   #3 (permalink)
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i cant pry out the courtesy light switch...any ideas on how to go about it?thnks
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Old 08-19-06, 10:47 AM   #4 (permalink)
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another job well done congrats.
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Old 08-19-06, 11:04 AM   #5 (permalink)
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Moving to DIY.
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Old 08-19-06, 01:17 PM   #6 (permalink)
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Did you guys remove the old solder like recommended by the links or just apply more solder on top?

Thanks for posting my car wouldnt start yesterday on the first two tries.
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Old 08-19-06, 01:24 PM   #7 (permalink)
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Quote:
Originally Posted by Scdfloordaycare
Did you guys remove the old solder like recommended by the links or just apply more solder on top?

Thanks for posting my car wouldnt start yesterday on the first two tries.

If you heat and reflow the solder...yo dont have to fully clean the old out....having been in the electronics industry since 1997 and having messed with electronics since I was a kid...just a simple reflow of solder is fine....the trick is getting the flow charateristics right....and its not really a "cracked" solder joint but more of whats called a "cold solder joint" just a FYI
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Old 08-22-06, 01:11 PM   #8 (permalink)
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Quote:
Originally Posted by korrupt1
If you heat and reflow the solder...yo dont have to fully clean the old out....having been in the electronics industry since 1997 and having messed with electronics since I was a kid...just a simple reflow of solder is fine....the trick is getting the flow charateristics right....and its not really a "cracked" solder joint but more of whats called a "cold solder joint" just a FYI
I've been soldering since 13 and the main relay is different. The main relay is subjected to a much more harsh environment. By not desoldering you run the risk of producing a high resistance. Desoldering has many benefits. It reduces resistance and allows for a much better flow characteristics.

What you can do is heat the solder to the melting point and use a straw to blow away the molten solder. Then apply the rosin core solder. Don't put a whole glob of it, just put the correct amount like shown on the links.

I have ran three independent test with the main relay. And on each case the main relay fails when it isn't desoldered.
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Old 08-23-06, 10:42 AM   #9 (permalink)
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This is a good link to resolder the main relay:

http://techauto.tripod.com/mainrelay.htm

This is a basically a simple resolder of a solder joint. There was not that much solder on the pin to begin with. Just add a little more solder, then try to use the solder iron tip to "stick" away as much old melted solder as possible then disgard (wipe it on wet napkin). You then added new from the end of the tip and let the solder flow down (make sure your solder iron is hot) and keep adding until solder is reflow up to the top of the lead (as in fig 4 of the link).

BTW, don't heat up the lead for a long time because it could possibly damage to the component that it is connected to on the other side of the board.

To desolder all the solder, you can use desoldering braid:
http://www.radioshack.com/product/in...rt&tab=summary

-Tat
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Old 08-21-09, 11:32 AM   #10 (permalink)
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Great post!!

Thank you for posting this! I have had my Legend for 4 years now and it always had problems starting when it was above 75 degrees. This year the problem got a lot worse. I had just put a new transmission in and I REALLY didnt want to scrap the car as a so called "Clunker." This DIY truly saved my Legend!
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Old 08-22-09, 05:33 PM   #11 (permalink)
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Thank you for posting this! I have had my Legend for 4 years now and it always had problems starting when it was above 75 degrees. This year the problem got a lot worse. I had just put a new transmission in and I REALLY didnt want to scrap the car as a so called "Clunker." This DIY truly saved my Legend!
Good to know a DIY I wrote many years ago still helping people!
Hope this forum will keep our beloved Legend from extinction !!

p.s. My 91 Legend coupe still running strong
-Tat
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Old 09-11-09, 12:19 AM   #12 (permalink)
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Thanks for this post, it saved me time and money!
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Old 12-10-09, 05:47 PM   #13 (permalink)
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Two years ago I gave my 94 Legend GS to my parents and it started having an intermittent issue where it would just shut off after it was running and not re-start for a few minutes later.

Fast forward to last week when it just wouldn't start. So I helped my dad diagnose what we were missing in the startup proceedure and when we checked the line to the fuel pump we weren't getting any voltage at all, fuses were okay so I ran a quick search here on the forums and found this thread.

Sure enough we took off the main relay, and right before our eyes was the broken solder joint just like you showed. Re-solder the connections and she fired right up purring like a kitten

Many thanks to the OP! You saved us a bundle! All the fix cost us was time and the tiniest bit of solder
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Old 12-18-09, 09:38 PM   #14 (permalink)
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Quote:
Originally Posted by TatNg View Post
Good to know a DIY I wrote many years ago still helping people!
Hope this forum will keep our beloved Legend from extinction !!

p.s. My 91 Legend coupe still running strong
-Tat
I just wanted to let you know that this saved me about 80 bucks and a heck of a lot headaches about 6 months ago. Did this fix in about an hour total, and I had never soldered before. The starting problem on hot days was causing me a lot of trouble and in some cases almost causing me to miss some really important meetings about an hours drive away during the spring! Haven't had a single starting problem since!
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Old 01-11-10, 08:13 AM   #15 (permalink)
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Just dropping by to thank this forum and all the great people who contribute to it. My Legend started with the same symptoms and sure enough I found this page and it was my exact problem. Took out the relay, it was pretty bad, resoldered and car is great again! Many thanks to all
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