Need an extension cord for Bosch relays
 

I'm trying to troubleshoot an electrical problem around a Bosch type (cube, 5 pin, 30/85/86/87/87a, etc) relay that is buried way up in the dash. If I could get a meter on the relay pins I could figure it out, but there is no way I can get to it.

I could make one, using the female end with wires that ships with the relay when you buy a new one, but no one sells a male end that I can find. I tried opening up a relay and gutting it to get a male end, but ended up destroying it.

Does anyone make an actual "extension cord" that has a Bosh male 5 pin plug on one end, at least 3 feet of 5 conductor wire and a Bosch female 5 pin plug on the other end ?

Can't you just put spade terminals on the end of the wires?

If I could see the socket that the relay plugs into, but I can't. Last night I started working on a solution using spade lugs set in potting compound (actually liquid epoxy) held in a relay cover for proper spacing. Should know tonight if it works.

You can cut the top off a relay, dig the guts out, and solder a relay socket with a pigtail to it.


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That's plan B. Already have the relay torn apart, waiting to see if plan A works. Still can't believe nobody makes one.

The testing harness does exist via IHC / Navistar Test Equipment PN ZTSE4596, although it is not cheap.

The overall length socket to socket is about 10".


https://navistarservice.snapon.com/S...umber=ZTSE4596

You're not kidding that ain't cheap!

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Just what I need if it were about 1/10th the cost and 2 feet longer.

Epoxy is setting up on my second attempt now. The liquid epoxy was too thin. I'm trying PC-7 now.

I made up this 3 foot long "extension cord" for cube relays. The female end is just a standard cube relay socket. Five wires running to the male end, covered with shrink wrap. The male end is five 3/16" crimp-on spade quick disconnects sitting in PC-7 epoxy contained in an old cube relay cover. Works good.


Figured out my problem in just a few minutes once I had this tool. The main power feed for the A/C system should come to one of the relays, but wasn't making it there. Turns out there was a plug that wasn't shown on the schematic that was about 6" upstream of the relay, hiding behind the A/C unit under the dash. It had come loose.


https://talk.classicparts.com/media/...l?d=1567185276

Nice! And nice!

Well, that was a good effort, and will provide troubleshooting assistance down the road too!

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