However, if I open the hood and giggle the relay on the motor, they will open. I pulled the relay but the contacts look clean. Could be the relay but the giggling makes me think there's a contact problem. Is this a common problem with a common fix? Ideas? Just get a new relay?

Thanks

 

It is probably the relay or the pins and socket it plugs into are corroded. Very likely if the rubber boot was worn and cracked for long letting moisture inside.

First use contact cleaner on the socket and sand the relay prongs clean. Push the relay in and out a couple times and see if that does the trick. The relay may also have bad internal contacts - they do wear out and can be hard to tell sometimes. It is a standard single pole double throw automotive relay. If you go real cheap like asian the are about 3 bucks, a bit over double that for a top line Hella.

Since the power wiring runs through that boot and is right next to the relay, that could also be the problem if you are actually hitting that a bit as you wiggle the relay around.

 

BRB,

Intermittent electrical problems are usually related to poor connections.

I had this same problem on both my 44's.

My culprit was the connector at the headlight motor. I removed the connector at the headlight motor (located next to the ignition coil)and with a set of needle nose pliers, GENTLY crimp the connector slightly closed. This will reestablish a positive connection.

My intermittent headlight problem has been solved ever since.