So my headlights pop up and turn on fine, but they sometimes don't go back down. Usually a tap on the relay gets them to retract and they continue to retract as long as I use them frequently. Once the car sits or I don't use them the problem resurfaces. I was thinking of pulling the cover off the relay and cleaning the contacts with some Deoxit spray, has anyone tried this? Trying to save it as it is uber expensive.

 

Nothing to lose IMHO. The headlight "relay" houses three or four actual little relays inside, doing the motor duty as well as turning the low- and high-beam filaments on and off.

At some point it will make sense to start opening these up, tracing all the internal components and circuitry, and figuring out how to repair/rebuild them as they move to NLA status. If you do open yours up, please take a few minutes to snap a bunch of detailed pictures of everything inside. For posteriority (those following behind you...)

 

Use a stiff piece of cardboard to clean the relay contacts, DON'T use sandpaper. It creates ridges and reduces the contact area but a lot.

 

Ted,

If you do fathom this one out I would also be interested to know what you did. Fortunately when mine packed up [similar symptoms] I had a spare from my late 90 S4 that plonked straight in and solved the problem but I guess it is only a matter of time before the currently installed one takes a dump. Possibly one of those things that Alan might be able to assist with/steer?

Rgds

Fred

 

Interestingly enough, I had this planned as today's Project. I also plan to clean the receptacle portion using Deoxit and one of those little toothbrushes meant to use between your teeth. One of the prongs is corroded so I'm assuming the part I can't see is, as well.

 

I started a thread a while back covering this , mystery searchlight syndrome , just take care removing the case. I used 1500 grit paper held with tweezers, again just be careful not to overdo it. Mine has worked flawless so far.
link http://api.viglink.com/api/click?for...E...%3C%2Fb%3E

 

Relay contacts are typically coated with a very thin silver (the metal) plating. Using an abrasive may gain you some time on a relay where the contacts have already been arcing and are damaged. It's not a good idea as a maintenance method on a good relay though.

Anybody have their old one(s) still around for some analysis for rebuild options? Might be a winter project for next year. I know there are a few different versions.

 

I have a failed one that I gave Kramer to tinker with a couple of months ago. Had a spare when it failed so I did a straight swap too. After 5 years, it still smells like a burnt circuit board.

 

crocus cloth does little damage and will shine up contacts. spray with deoxit.

 

I have had good long term results with some 600 grit paper then a drop of deoxit 100 to clean the contacts of the HL relay

 

The "Don't use sandpaper under any circumstances" came form an electrician that deals with electric motors and relays every day. So as a fine grip sandpaper will get things going, it will screw up the contact.

 

It's a temporary fix that will work for a while. No matter what, the contact has worn through the plated surface. Anything you do from now on will only have a fraction of the life of the original. That's why your electrician said what he said. It has almost nothing to do with the surface finish (within reason) and anything above 600 grit will be ok.

 

I would rather adjust the contact points and have the relay operate on an area of the contact that hasn't been used and burnet up by the relay. This way it will operate on untouched points and should last as long as before.

 

I found a local source for Deoxit but they had to order the 100% concentrated stuff. Once it comes in I am going to pull the ce panel and give everything a good once over and open up the relay and clean it. I will take some pics when I do.

 

the deoxit will help protect the contacts from carbon/ arcing,
so smoothing the surfaces will restore the original flatness and new surface area should be exposed.

I do understand about not grinding off the plated surface but after one side has a mountain and its full of carbon it wont pass current.

So suffice to say my HL relay has been working trouble free for the last 3 years,
and this is after I cleaned the contacts and added a drop of deoxit to each contact