most of the time when contacts stick they stick closed, sounds like the coils have gotten weak

 

Or the contacts can be pitted and worn..."smoked" so to speak I guess that you don't have some backup relays laying around to try out? After I smoked two relays, and everyone else here started having relay problems, I started keeping 3 backups in the glove box

 

Nope no backups but the new relays and sockets get delivered this friday

 

maybe thats why






























jk hope you figure it out by the sounds of things ill bet its your realys

 

A little update. All the new stuff came in today, however i found the issue... The single ground wire i had corroded to the point where it was brittle... This was the 1 spot in the entire harness that was not soddered and heat shrunk.... So it was my dumbass that caused it. Also i had the entire harness grounded threw 1 single 12 gauge wire... This was another my bad... If you look at the schematic, the harness grounds in one spot, however there are 2 wires... I joined the wires somewhere in the harness and it was grounding through 1 wire... I noticed the power wires had no heat on them, but the ground wire was heating up, i believe running 2 wires will fix that...

Also as a side note, i put my clamp meter on the power wires, when the fans kick on high they spike to ~12 amps for a brief second, when they are running on high they only pull 2-3amps...

 

Glad it was an easy fix

 

Glad that you figured it out, even though you're making a new one anyway. At least now you know the weak link and know how to improve on it. Good info on the amp draw of the fans too, thanks Corey ...I feel better about running 20/30 relays now, although I will replace them with 30/40's if and when they burn out

 

Corey can you post up the links to the new goodies for the harness? Im copying your setup exactly

 

I will PM you the links and i will try to get those PIDs to you tonight.

 

I have seen the terminals to the efans at the motor loose tension, overheat overtime, create higher resistance, melt and then the fans no longer work. Just a little FYI.