L400 Glow Plug Relay Repair.

[psilosin]

Just a heads up that it is possible to refurb your L400 Glow Plug Relay quickly and easily. Definately worth a try before thinking about dropping $180+ on a new one!!

Endless day of data crunching at work today so while the genetic algorithms were breeding I decided to give it a go. I pretty much just followed the instruction on this link (http://www.pocuk.com/forums/viewtopic.php?t=75294) from the UK Pajero forum.

One variant, my coil had a measured resistance of 3.4ohms rather than the 2.7ohms listed for the Paj unit (the relays are similar not exact so that might even be the proper reading for teh L400 unit). I didn't even go through as much effort as the OP (original post). Just disassembled and cleaned contacts. My contacts were in poor shape...lots of green corrosion and black charring...30 seconds of rubbing with a pencil eraser and they are nice shiny copper again. Neither the contact bar or pad were that worn so I didn't bother flipping/rotating as suggested in the OP. I also replaced the tape around teh coil that had disintegrated (don't tape over the wire bend though, that is the needed flex for when the coil moves up/down when activated/deactivated).

Result = relay works like new. 5 minutes well spent.

My ghetto repair/testing setup made up of whatever I could quickly find at work. lol.

relay.jpg

[jessef]

...30 seconds of rubbing with a pencil eraser and they are nice shiny copper again.

Ace!

[92pajero]

100 bucks a piece new in box from denso
I get them from my supplier in toronto so even with shipping no more than 115 bucks
let me know

[psilosin]

Nicer price for sure...but still $80 more than I would pay for a simple relay. If the rebuild didn't work I'd just keep using the $20 generic 120amp that is in there now.

[92pajero]

True, still more than a simple relay, but a simple relay in my experience most times will not last due to current required to heat the GP's. Let me know how it goes and which relay you do wind up using. I would like to add this to my list of fixes.

Kelly

[thedjjack]

Warn sells 100% duty cycle relays for big loads.....winches draw big amps.

[psilosin]

Kelly, now that the original relay is repaired I will be putting it back in whenever I get around to it mainly because I could not fit the aftermarket 120amp relay in the stock location since it was like 2x as big as the mitsu unit so it is in a bit of a jerryrigged temp location. Stock looks cleaner tucked away in the back.

The factory relay is just a simple relay though...just a coil and some contacts...nothing special about it from any other relay of similar duty. Pretty much the same inards as the $20 120 amp generics. Not sure the cost of the warn relay but its probably cheaper and more heavy duty than oem and would be a solid choice.

[EnviroImports.com]

nice work, alot of people are running into this problem a DIY solution and cheap is great.