After a prolonged diagnosis procedure ensuing from a no-start situation, I found the root-cause to be rotted insulation around the inside connectors to my Radio Suppression relay (relay p/n 3544322). Despite swapping the relay with a known-good unit, I was unaware the connectors weren’t actually making contact because they had slipped down inside the connector body. Heat, time and vibration had taken their toll. Have since found the same issue on the Aux Fan relay connector.




Avoiding the cost and hassle to order up new connectors part #<3523813-8> as discussed in the FAQ, I pursued an alternative solution that was cheap and repaired within 24hours. The repair is weather tight and did not entail cutting/crimping in new wires or soldering. As the photo shows, I used aquatic tank AirLine tubing procured from a pet supply store (Petco SKU 1446614-8FT for $5 USD). The inner diameter is just right to hold the female connectors yet small enough to make a tight fit around the base of relay pins (what found at local hardware stores was too big).





The hose was cut to approximately 1-1/4inch length to fit lengthwise inside the connector body. The 1/8 inch of gap between the female connector and tube end seals around the base of the relay pins when connected/ making the weather seal. The aft end was filled with JB Weld to seal and keep the wires from shifting inside the tubing. After a day of drying, I routed the wires through the bottom end of the connector body and then reconnected each wire individually to the relay pins and then shoved relay onto the connector body. All is well – car starts.

I still have 7.5 feet left – enough to do a fleet of 240,740 and 940s!

Best regards,
TurboCT

1991/740T – 204Kmiles.