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Planojc · 07-05-2019, 08:03 AM

I have found many Borg-Warner relays with as much as a two volt drop due to bad connections inside the relay. If you remove the cover you will see that all connections are made with rivets and over the years corrosion sets in and you get a voltage drop. The rivet connection where the fuse holder connects is usually a place to start. I clean all rivet connections and using a good flux, solder all these connections. You can also have a drop through the ignition switch that will cause the same problem. I have a test setup with a battery and sol. that I can use to check the voltage going in and out of the relay and after doing the above, if you have proper output from your charging circuit it will work every time. Another thing that helps is to go with an alternator, even if you are running 6v.

07-05-2019, 08:03 AM	#12
Planojc Senior Member Join Date: May 2010 Location: Plano, Texas Posts: 839	Re: overdrive I have found many Borg-Warner relays with as much as a two volt drop due to bad connections inside the relay. If you remove the cover you will see that all connections are made with rivets and over the years corrosion sets in and you get a voltage drop. The rivet connection where the fuse holder connects is usually a place to start. I clean all rivet connections and using a good flux, solder all these connections. You can also have a drop through the ignition switch that will cause the same problem. I have a test setup with a battery and sol. that I can use to check the voltage going in and out of the relay and after doing the above, if you have proper output from your charging circuit it will work every time. Another thing that helps is to go with an alternator, even if you are running 6v.