my fuel pump relay keeps burning out
My 1999 Dodge Ram 1500 would start to sputter after about 5 minuets of driving, like it wasn't getting enough fuel. The fuel pump is good, but I've replaced the fuel pump relay and still have problems. When the symptoms occur the relay is hot to the touch. I tested the old relay in accordance with the repair manual and I have continuity between terminal 30 and 87, but not between 30 and 87A, which is the opposite it should be according to the manual. Also the positive terminal on the battery corrodes quickly, within a couple days of cleaning and greasing it. I think it may be drawing too much current. Any ideas what may be causing this? Also how would I check to see if there is a short in the fuel pump curcuit. The truck just came out of the shop recently for repairs to the parking brake cable and replacement of the serpitine belt and adjuster, not sure if something may have just gotten knocked loose as the problem started shortly afterwards.
Your pump may be delivering enough fuel but it may draw too much power to do so. I would recommend bench checking it with an ampere meter. The old relay may be "welded" in the closed position by the current going through it. Corrosion on just one terminal is a sign of a broken seal between the battery's inside and the casing causing some of the electrolyte to get out through the capillary effect. I'd recommend replacing the battery.
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