Yellow Main Relay Fault (Td5)

[maxthomas]

I was driving along last night and I started to sense a strong electrical/plastic burning smell. A few moments later my Defender began to lose more and more power when under load or medium to high acceleration. It felt like a misfiring/running out of fuel. So I pulled over and did some investigating, with my nose. I have moved all my electrics from underneath the drivers seat into an Exbox under the centre console.
When I opened my Exbox I found a blown yellow relay with the following details:
FORD
G1UHD
93BG14N089B1B
V23136B1X33
12V
40A

https://www.aulro.com/afvb/images/imported/2015/07/316.jpg

https://www.aulro.com/afvb/images/imported/2015/07/317.jpg

https://www.aulro.com/afvb/images/imported/2015/07/318.jpg

https://www.aulro.com/afvb/images/imported/2015/07/319.jpg

https://www.aulro.com/afvb/images/imported/2015/07/320.jpg


After some research online it appears to be a multifunction relay. This morning I went to Greg Tunstall in Cleveland and he sorted me out with a new relay to suit.
It has the following details:
Tyco Electronics
V23134B52X127
YWB10012
12V

https://www.aulro.com/afvb/images/imported/2015/07/321.jpg

https://www.aulro.com/afvb/images/imported/2015/07/322.jpg

https://www.aulro.com/afvb/images/imported/2015/07/323.jpg

The vehicle is now running fine. I bought a second backup relay to keep in the car in case it happens again.

[jabber]

Did you also fix the insulation on the culprit wire? Any reason why it been stripped back so far?

[maxthomas]

Yes I bought a new plug as well. I believe the insulation was stripped back due to heat of the relay blowing as it wasn't like that when I moved it all into the Exbox 8 months ago

[Patchy]

More of an FYI but I see this type of fault quite regularly with my work. Usually this damage is not actually caused by a faulty relay but more that the terminals loose they're tension on the pins of the relay and continually arc out causing heat that melts the plug and insulation off the wire aswell as killing the relay...

if you test the terminals for tension using a smooth spade terminal you'd find they just fall apart with no to little effort. Best to test other relay plugs while going through and repair all at same time. Either replace with good quality terminals or squash them a little, the first option is obviously the better but both work haha

Hope it helps