Wrong fuel relay installed--burnt relay fuse box now--truck stalls with new relay as it it shorting out?

on Dec 6/07 we took our 1996 Suburban for a block heater and u-joint to our local service station. After picking up truck we got 5 miles out and realized we were over red line--they neglected to replace the antifreeze.Towed us in--replaced fluids-sent on way.8 days later fuel relay goes-replaced it.2 weeks later fuel pump goes-replaced it.2 weeks later we started stalling out-sometimes completely,sometimes just loss of power for a second or two.Took it to garage--said possible C02 sensor-sent on way-still stalling. 3 weeks we stalled,one day it wouldn't start. Towed us in.Service station claims they found the problem--the fuel relay fuse was burnt and the connection it plugs into was burnt so they cleaned up all connections and sent us on our way.5 days later it starts stalling(9 times/7 miles)Take to a different mechanic--found problem--fuel relay is red hot--it is the wrong relay!now we have the right relay, connection inside is still burnt. How do you change connections in fuse box?Wrong fuel relay installed--burnt relay fuse box now--truck stalls with new relay as it it shorting out?If the fuel relay is burning up, then you have an issue with either poor connections in the fuel circuit, poor grounds in the circuit or the pump is pulling too much amperage. Take the vehicle to the dealer. I would install an ammeter and see what the current draw is on this circuit. I would then perform voltage drop tests to check for poor connections. This problem is most likely out of the service station's grasp.Wrong fuel relay installed--burnt relay fuse box now--truck stalls with new relay as it it shorting out?Well some fuse boxes you'll find unused relay sockets or fuse sockets and you could then you proper wire and connectors to simply pop an old circuit out of a vehicle at the auto wreckers and connect it up to the old box.Or you could buy a universal relay housing that you could simply add to the old fuse box via proper gauged wires or replace the whole fuse box

If anybody knows how to peel and wrap wires so they can be soldiered and then a special heat sink tube added as insulation then I'd probably change the whole fuse box and by the way if it's the under hood fuse box their actually called power distribution centres and aren't that hard to replace if you've the basic know how.After all the fuse box might be melted more then you think it is and it's not good to use the old relay socket.But basically the wires you see going to the relay via connectors should pop out but I'm not sure on that vehicle if their like that.



Hope that helps and best of luck.By the way I would check for bad or burnt or melted ground wires too , plus to me getting another power distribution centre would help you in figuring out whats the best way to fix that problem.Wrong fuel relay installed--burnt relay fuse box now--truck stalls with new relay as it it shorting out?WOW! Sounds like it's time to call an attorney.Wrong fuel relay installed--burnt relay fuse box now--truck stalls with new relay as it it shorting out?hi there..

If the mechanc says it ok and its working you may not have to do anything other thatn check the wires to make sure they are not burnt through casuing a shortage.

The reason it burnt was becasue the relay was to low rated drthe system tried to draw too much power though it so it got too hot

If i remember rightly the relay is in the fuse box under the hood yep....

You could get the repair workshop manual and look it will show you haw to replace the fuse box.... I am not 100% sure but i think some suburbans the fuse box is wired in such away that it you would need to buy a complete wiring harnes ... which i would not attemp to fit myself ...

You could unscrew the fuse box look under ans fee how its wired and if you can by pass the connector adn splice in a new one

Or you can clean the connectors and put the relay back in the fuse box.....