XJ TJ ZJ Flasher Relay Repair

[JeanLuke]

So, twice in the last year my indicators and hazards randomly stopped working. I figured it was time to replace the relay (around $50) or fix it (around 1 hour). I figured that $50/hr isn't bad for an otherwise lazy Sunday afternoon (and replacing it would take close to that long anyhow).

Here's a write-up:

1/ Remove the panel above the steering wheel. It is clipped in each end towards the bottom. I got mine off with fingers at each lower corner. Just pull towards the steering wheel. You can see the clips in pictures below.

2/ Remove the panel below the steering wheel. It's held in by two upper philips-head screws, two lower 10mm bolts and one philips-head screw on the end (you'll need the door open to get it). It's then clipped to the centre panel.




3/ Look up above the fuses. The target is the blue relay. Yours might be black. It's the one that sticks out the most. Grab it, wiggle and pull and it should come out.

[JeanLuke]

4/ Pry open the two tabs with a screwdriver each side.



5/ Note the slot in the back of the cover. When putting it back together, the PCB side goes there.



6 / Sit yourself down with a magnifying glass and check for cracks. Mine was on the closest pin. It was tiny. You won't see it in the picture. Tip: If you have poor close vision (like me) get somebody younger to help here.



7/ Carefully melt and re-solder all the pins. I also lacquered my PCB for good measure. Tip: Keep lacquer away from the relays. It could make them stick.



8/ Re-assemble - just do the above in reverse. Tip: The vertical centre pin goes to the bottom.

[Jimmyb]

Thanks so much for the comprehensive post!! Got this exact problem at the moment.

[JeanLuke]

I've since edited the original post with a few extra tips. See http://www.ausjeepoffroad.com/forum/...d.php?t=154902