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94 t800 relay melted

Discussion in 'Heavy Duty Diesel Truck Mechanics Forum' started by Mr79W900A, Sep 3, 2020.

  1. Sep 3, 2020 #1
    Mr79W900A

    Mr79W900A Light Load Member

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    Mar 4, 2019
    British Columbia
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    Hey guys my 94 t800 marker lights are acting up. The marker lights and all dash lights will work fine a bit. Then the relay starts clicking like crazy and the lights flicker then stop and repeat. The fuse plug is melted a bit where it plugs in now. Also the relay would be crazy hot. I’m guessing it’s a short?? Wire rubbing somewhere. ? Or have you guys had a similar issues and it’s something else. Gonna check the main power to the fuse box etc this weekend but Pretty sure that’s fine.
     
    Mr79W900A, Sep 3, 2020
    Mr79W900A, Sep 3, 2020
    #1
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  3. Sep 4, 2020 #2
    AModelCat

    AModelCat Road Train Member

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    Canuckistan
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    Is your fuse panel behind the clutch pedal, on the firewall?

    They've been known to corrode due to windshield leaks.
     
    AModelCat, Sep 4, 2020
    AModelCat, Sep 4, 2020
    #2
  4. Sep 4, 2020 #3
    Heavyd

    Heavyd Road Train Member

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    Melted connectors like that are normally caused by weak connections common in older units. The weak connection causes increased resistance and the increased resistance causes heat. Many terminals inside the connector have a contact tang or tongue that gets spread wide over the course of time and just needs to be rebend back into shape to make a good tight connection again. Sometimes you can use a small screwdriver or pick to reshape them, or just wire in a new relay socket if you have the room.
     
    Heavyd, Sep 4, 2020
    Heavyd, Sep 4, 2020
    #3
    lester, AModelCat and spsauerland Thank this.
  5. Sep 4, 2020 #4
    BoxCarKidd

    BoxCarKidd Road Train Member

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    If the connectors for the breaker and or fuse have been overheated I rewire it into an unused breaker-fuse location. Requires pulling the panel off front of firewall. Four hour job? Maybe 3, its been a while.
     
    BoxCarKidd, Sep 4, 2020
    BoxCarKidd, Sep 4, 2020
    #4
    spsauerland Thanks this.
  7. Sep 6, 2020 #5
    Mr79W900A

    Mr79W900A Light Load Member

    117
    72
    Mar 4, 2019
    British Columbia
    0
    Yup the old owner had a windshield leak and never fixed it. I will be popping the panel off tomorrow to see. Pretty sure it’s what you guys are saying. Loose and or corroded connectors or both. It’s the only one doing it. I have two like new spares right above it so I’ll rewire into that one cause this one is too far gone for my liking. Getting windshield resealed next week. It drips in pretty good when raining hard. I tucked a towel in there too see and it’s pretty wet. So the towel has stayed till I had time to reseal
     
    Mr79W900A, Sep 6, 2020
    Mr79W900A, Sep 6, 2020
    #5
    BoxCarKidd Thanks this.
  8. Sep 6, 2020 #6
    Mr79W900A

    Mr79W900A Light Load Member

    117
    72
    Mar 4, 2019
    British Columbia
    0
    Yup you bet. Ya I heard that as well.
     
    Mr79W900A, Sep 6, 2020
    Mr79W900A, Sep 6, 2020
    #6
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