relay question - : Jeep Wrangler JK Forum
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post #1 of 4 Old 10-21-2009, 05:43 PM Thread Starter
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relay question

what would cause my relay to "fry" that i have hooked up to my 130w fog lights? i have had no issues with the two windshield mounted lights...they are the same kit with the same relay????

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post #2 of 4 Old 10-21-2009, 08:12 PM
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Bad relay (probably this one), Wire length pushed current draw over max, Short on lights.

Is it hard wired to the battery or does it run off the fog light switch? I think the fog light control voltage runs on the came concept as the headlights. It's not straight DC, Its pulsating DC and your relay may be sensitive to it.

Change the relay and see if it happens again. You were probably the lucky owner of a defective part. Try to pick up a 30/40 amp if you can. They probably set you up with a 20amp relay to begin with, which would max it out on start up.

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post #3 of 4 Old 10-21-2009, 11:42 PM
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FIRST: make sure you DO NOT have it attached to the factory wiring!

I'd say replace it, and check the circuit to see if it is overheating. If there is no heat on the wires or relay (don't touch light housing or bulb {gotta include that to c.m.a.}), then you were the lucky one with a bad relay from the get go.

You need 21.666.... amps for 2 lights on one circuit, and 43.333.... for all four lights on the relay.

Now if you are getting some heat on the wire... You need to check the wire length, gage, and material for proper sizing.

If you are getting some heat on the relay... You need to check to make sure the relay is rated for over 25 amps.

If you are getting some heat on the light... OK. They do that.

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post #4 of 4 Old 10-22-2009, 11:03 AM
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make sure that you have a fuse as close to the battery as possible. check everything with a volt meter and not a test light, ever. try running the relay of of a switch for a while, though I don't see a reason since a relay can flip with very minimal voltage though I could see where the can bus flicker could cause this and the need to add a capacitor just like the headlight upgrade fix for hid conversions. bad relays are rare but they happen, I would double check all of your connections and make sure nothing came loose that would raise the resistance values and cause the relay to over heat. check as posted for proper sizing of the wires and relay, may want to think about adding a second relay if you can't find one large enough.

keep in mind the more amps through the relay the more it will arc and will cause the relay to either stick latched or burn up. this was the case in a lot of starter kill relays back in the day.
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