Alan,
Thank you for the write up. I will be doing this soon and post the results. I have a couple of more questions.
Where do i get the female pins that goes into the CE?
Would a 53 relay work?
Are the points marked on the back of the CE panel?
Thanks
Bilal

"it seems like a potential repair would be to drill a hole through the extension piece on #4 where the plastic pin was and insert and glue in a stronger (than plastic) metal pin. Not remembering exactly what it looks like, though, I'm not 100% sure that's doable."

That's it! Rebuilt many (too many to remember) that way.

Bump

Anybody has the female clips that go into the CE for the relay?
Bilal

'53 or generic Bosch style SPDT relays will both work. Genuine Bosch or Tyco.

Everything is marked on the front of the panel. send me a PM w/ email and I'll send you some more details on the relays. You can get the stock large relay terminals from Eagle Day or Vehicle Wiring Products (UK) - I got a lot from VWP(UK). I belive Roger (ROG100) also sells them individually. You can also use Ford standard terminals - though they are not such high quality.

There are some techniques that are usefiul to know for removing relay sockets & terminals.

Alan

My relay is DOA! time for some solder work. Thanks for the great write up here.

http://www.nospoons.com/Porsche/dead-relay.jpg

Wrapped this up today with the $9 radio shack relay. Bought it at the mall! Nice to see that at least some radio shacks still are true to their origins.

Tips: Remember REMEMBER DO NOTDO NOT crank the heat all the way up on your soldering iron. My board now requires a couple extra jumper wires because I cooked the PCB contacts right off the @$%^@! board.

Solder wick or a real vacuum solder tool is your friend. After all the electrical work I do I'm amazed I didn't have one of these 10 years ago.

I'm going to add another tricky bit to my install with an extra switch to enable/disable the compressor, but use the stock signals and switching to kick on both fans for those sit-on-rt66-at-100F moments. Or anywhere else I want to flog the crap out of the car and don't car about having the AC load on.

I'm not sure I'm understanding your reason for the switch... can you explain more?

Alan

I want to be able to kick both fans on "HIGH" on demand without turning on the AC.

"Wrapped this up today with the $9 radio shack relay."

Hopefully, you checked the clutch current, as the original relay was destroyed by excessive
compressor clutch current, i.e. Much more than the normal current of about 3 amps.

In the past this car fragged two different compressors, that's what took out the relay. I'm 70% done with complete cleanining and flushing of the entire system.