PSA: KAE Fuel Pump Relay

Post by **bmdubya1198** » 14 Feb 2018, 17:50

Just thought I'd post this on here rather than leaving a review on FCP or elsewhere. First off, I didn't buy this relay new. I got it from a car at the junkyard, and it looked (and still looks) brand new.
I ran this relay for probably a year, maybe 5k miles. This is what it looks like now. You can see where it burned out. Fortunately this failed in the driveway when the car wouldn't start one morning, and I carry a spare in the glovebox. I highly recommend keeping a spare in your car, this can save you a lot of time and aggravation worrying about a tow. Failures aren't uncommon. Just make sure you have a T25 bit or screwdriver in your car to remove the cover.

Anyway, the lesson here is buy genuine. I'm once again running my 20 year old, 183k-mile relay with no problems. And yes, I have a new (used but tested) spare.

Post by **jtp** » 14 Feb 2018, 17:55

Good to know thanks

Post by **FlyingVolvo** » 14 Feb 2018, 18:27

+1

I've gone through 2 KAE fuel pump relays in the last 4 years. Original lasted 14 years. I, too, have learned my lesson.

Post by **erikv11** » 14 Feb 2018, 18:41

Great info, thanks for posting.

I bought a brand new OEM relay back in January. Not due to failure just as insurance. It was hard to swallow at $56 when I have like 5 spares in the garage, but the car is with my kid 3 hours away. I'd rather swapping in the glove box spare wasn't required.

WhatAmIDoing · Post by **WhatAmIDoing** » 14 Feb 2018, 20:36

If a KAE relay is your spare, better have 2 spares. I went through 3 in one day (glad I bought from FCP). And that KAE is now on it's way out after little over a year.

Post by **erikv11** » 14 Feb 2018, 23:12

My spares are all old factory Volvo ones all still working, I'll take that over a new KAE any day.

Post by **abscate** » 15 Feb 2018, 04:21

I'm still on my original at 200k. I did take it out and dremelled the terminals which were showing signs of thermal damage. I wonder if that helps extend life? Has anyone done root failure analysis on a dead one?

Post by **jreed** » 15 Feb 2018, 05:07

This is the best thread on fuel pump relay failure causes that I know of: viewtopic.php?f=1&t=9681

Main causes (not necessarily in order):
Cracked solder joint between pin and board
Electrolytic capacitor failure
Diode burn out

Post by **abscate** » 15 Feb 2018, 05:19

jreed wrote: ↑15 Feb 2018, 05:07 This is the best thread on fuel pump relay failure causes that I know of: viewtopic.php?f=1&t=9681

Main causes (not necessarily in order):
Cracked solder joint between pin and board
Electrolytic capacitor failure
Diode burn out

That's excellent. Added the part number to that thread for search, 9434225

Covers relays from 1993-2000!

Post by **wizechatmgr** » 15 Feb 2018, 06:30

Would highly suggest checking your other relays while you're in there folks. Keeping a generic 4 pin 50A relay in the glove compartment will make your life a LOT easier. You can use a generic relay for the fuel pump, but it will be pumping any time the car has power and is on if I remember correctly. Good in a jam, not necessarily good longer term.

I happen to keep one of these on me, as well as an older/intermittent fuel pump relay.
https://www.amazon.com/gp/product/B003C549SY/

Would suggest carrying a spare starter relay - though if you keep a 24" piece of wire in your car you won't need it to get home.