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Smokin' Relay
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BoneMachine
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PostPosted: Sun Nov 25, 2012 1:29 pm    Post subject: Smokin' Relay Reply with quote

So, the battery kept going dead and for some reason wouldn't take a charge. It's a fairly new battery so.......... I disconnected the ground and it charged up just fine. Hooked up the ground, jumped behind the wheel and turned the key. It just barely turned over, sounded like a dying battery and then I saw a plume of smoke. It came from the battery relay under the driver's seat..
Obviously, I need to replace the relay, but is there anything else I should be looking at that might have caused this problem?
Here's a picture of the melting connector.
Image may have been reduced in size. Click image to view fullscreen.

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ZsZ
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PostPosted: Sun Nov 25, 2012 1:41 pm    Post subject: Reply with quote

I think this was the split-charge relay.
Check for melted wires/connectors in other places too.
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Timwhy
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PostPosted: Sun Nov 25, 2012 1:51 pm    Post subject: Reply with quote

Isn't that wire the one that goes to the fridge
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BoneMachine
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PostPosted: Sun Nov 25, 2012 1:56 pm    Post subject: Reply with quote

Timwhy wrote:
Isn't that wire the one that goes to the fridge


Hi Tim, It's a weekender. I do have a portable fridge, but it plugs into an outlet supplied by the aux battery.
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Last edited by BoneMachine on Sun Nov 25, 2012 5:01 pm; edited 1 time in total
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Timwhy
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PostPosted: Sun Nov 25, 2012 2:12 pm    Post subject: Reply with quote

That burnt wire is from the starting battery, on the 30 position on the relay? The blue wire is from the ignition.
Small red/black to ground, and the other large red wire to " + " side of aux battery?

If you have an Autozone close by they sell these for about $5.
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Jake de Villiers
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PostPosted: Sun Nov 25, 2012 2:54 pm    Post subject: Reply with quote

BoneMachine wrote:
Timwhy wrote:
Isn't that wire the one that goes to the fridge


Hi Tim, It's a weekender. I do have a portable fridge, but it plugs into an outlet supplied by the aux battery under the passenger seat.


The battery under the passenger seat is the main/starting battery - the one under the driver's seat is the coach/house battery.
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thatvwbusguy
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PostPosted: Sun Nov 25, 2012 10:24 pm    Post subject: Reply with quote

The relay under the drivers seat is not a standard 5 pin relay like you would find on the shelf at AutoZone, it is a "Dual 87" relay. Most common 5 pin relays have one #87 terminal (normally open) and one #87a terminal (normally closed). The dual 87 relay has two normally open outputs.

There are several different pinout arrangements for automotive relays. They all look pretty much the same, but function very differently. The terminal numbers are typically listed on the base of the relay next to the 1/4" tabs.
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