Fuel pump relay issue

[racertim]

I have a 1996 Tahoe with 4wd, 4-door. Engine quit like no fuel. Replaced fuel filter, but no pressure. Replaced pump but still dies or will not start. Pulled out relay, very warm, almost too hot to touch. Put it back in, started right up. Every time it dies I repeat the procedure and it starts back up. I remember a vague conversation once where someone told me that their S10 had that problem and they replaced the fuse box and it fixed it. Does this happen with the Tahoe also? Why is the box so hot? Any other ideas?

 

[SunlitComet]

Sound like shorting, loose or corroded terminals/wires. Is it just the relay that gets hot or the whole power block? Any signs of arcing burning, melting? Have you tried replacing the fuel pump relay?

 

[racertim]

reply

The whole block is hot. I did put a new relay in with the same results. I do not see any obvious signs of melting of arcing.

 

[SunlitComet]

you will have to disconnect your battery and flip your power block over-upside down. You probably have damaged wire insulation or a wire that maybe broken and it causing a high resistance short on the bus bars.

 

[racertim]

thanks

I will check that out!

 

[Trippers99hoe]

my 96 chevy truck did this...I went to the salvage yard and bought the box and wiring harness replaced it all,cost me $100 and have had no problems in 6 months.

 

[SunlitComet]

Also check the bus bars on the block for heat discoloration.

 

[Trippers99hoe]

my 96 chevy truck did this...I went to the salvage yard and bought the box and wiring harness replaced it all,cost me $100 and have had no problems in 6 months.

Look very carefully at the box where the relay plugs in.Mine was melted and the relay was loose .....I thought about just replacing the box but when my junkyard dog sold me the complete harness ,I just thought it would be better to swap it out.