Plug for Fuel pump relay damaged - How do I fix this? See Pic

Discussion in 'General Maintenance/Repair Questions' started by Vince_nj1, Aug 25, 2012.

  1. Little Ducky

    Little Ducky Active Member

    936
    Jun 5, 2017
    Chattanooga TN/Dickson TN
    1998 SeaRay 290 Sundancer
    Twin EFI 5.0L w/Alpha 1 drives
    What size relay is it? 30 amp? 40 amp?

    You can buy relays with a prewired socket so all you need to do is splice it in. Use some water resistant heat shrink butt connectors and you should be good to go.

    [​IMG]

    Do you have a picture of the damage you can post?
     
    Last edited: Jan 31, 2018
  2. Vince_nj1

    Vince_nj1 Active Member TECHNICAL Contributor

    Aug 25, 2008
    North Barnegat Bay
    2006 320 V-Drives 6.2s, Bow Thruster, Generator, Raymarine C80, Radar, Fish Finder
    6.2 Horizons 320HP
    You will need a removal tool, a crimp tool, various replacement connectors and new relay from Ballenger Motor Sports. This is what I ordered, I may have ordered some metripack that I didnt need, but it was cheap enough I didn't care.

    https://www.bmotorsports.com/shop/index.php/cPath/111_112_170

    CONN-33555 GM Delphi / Packard - SPDT Relay, 30AMP, 12 volt with skirt for sealing MP 280 $9.991 x $9.99 CONN-91254 GM Delphi / Packard - 2 Way Metripack 150 Plug Assembly, Black $3.491 x $3.49 CONN-31568 GM Delphi / Packard - 2 way metripack 280 sealed connector assembly, black (connector and TPA) $3.491 x $3.49 CONN-75818 GM Delphi / Packard - 2 way Walbro 450 pump connector Kit & larger fuses $5.251 x $5.25Sub-Total:$22.22UPS Ground (Estimated 2 Business Days):$12.37Total:$34.59

    Removal Tool
    TOOL-02001 GM Type Metri-Pack ( Metripack ) and GT Removal Tool - Thin Blade ( 150, 280 and others ) $6.99

    Crimping Tool

    [​IMG]
    [​IMG] [​IMG] [​IMG] [​IMG] [​IMG]
    Pricing
    1 + $31.99
    5 + $31.49
    10 + $30.99
    50 + $28.49
    Information
    Bmotorsports Part # TOOL-01000

     
  3. Vince_nj1

    Vince_nj1 Active Member TECHNICAL Contributor

    Aug 25, 2008
    North Barnegat Bay
    2006 320 V-Drives 6.2s, Bow Thruster, Generator, Raymarine C80, Radar, Fish Finder
    6.2 Horizons 320HP
    I forgot that you also need this (which has a relay with it)

    GM / Delphi Sealed Metri-Pack ( Metripack ) 280 Medium Current Sealed Relay Kit SPDT 30 AMP Part # CONN-75575
    [​IMG]
    [​IMG] [​IMG] [​IMG] [​IMG] [​IMG]
    Pricing
    1 + $19.49
     
  4. lpvanam

    lpvanam Member

    105
    Aug 8, 2009
    Silverdale, WA
    2006 Sea Ray 340 Sundancer "Even Moor Memories"
    Dual 6.2L MPI - V-Drives
    Thank you
     
  5. Todd320

    Todd320 Active Member

    381
    Jul 21, 2016
    St. Petersburg, FL
    2007 Sea Ray 320DA
    Twin V-drive 5.7L 350 Horizon
    I did a similar repair last May. I cut off the fuel relay harness, spliced in 4 quick connects, then connected them to an automotive relay, 40A, 14v, have not had any issues since. Prior to that, I replaced the relays multiple times and mechanic fixed the harness once. I did shrink wrap the connections between the quick connects and the relay to try to keep any corrosion at bay. I tried a 30A 12V relay initially, lasted about 15 minutes. Relays were about 9-15$, quick connects were cheap. I also purchased the new MerCruiser replacement harness which is suppposed to correct the issue, but never installed it since this has been flawless for the last 15 trips.
     
  6. Seascape2

    Seascape2 New Member

    7
    May 5, 2017
    Florida
    320 SeaRay 2002
    T350 w/shafts
    Great post!
     

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