Gather Materials:
1. Replacement relay box (salvage yard or online retailer)
2. Electrical tape
3. Sandpaper
4. Wire strippers
5. Electrical connectors (crimp connectors or solder)
6. Heat shrink tubing
7. Rust remover or white vinegar
Disconnect the Battery:
1. Locate the negative (-) terminal of the car battery.
2. Loosen the nut or bolt that secures the negative cable to the terminal.
3. Remove the cable and make sure it doesn't touch any metal surfaces.
Locate and Remove the Corroded Relay Box:
1. Open the hood of your car.
2. Find the relay box that houses the affected relays.
3. Disconnect the electrical connectors from the relay box.
4. Remove the mounting bolts or screws holding the relay box in place.
5. Carefully remove the corroded relay box.
Clean the Relay Box:
1. Use a wire brush or sandpaper to remove as much of the corrosion from the relay box as possible.
2. Spray the relay box with rust remover or white vinegar.
3. Allow the rust remover to sit for several minutes.
4. Rinse the relay box with water and let it dry completely.
Install the Replacement Relay Box:
1. Place the new relay box into position and secure it using the mounting bolts or screws.
2. Reconnect the electrical connectors.
Test the Relay Box:
1. Reconnect the negative battery (-) cable to the terminal.
2. Start the car and check if the relays are functioning properly.
Protect the Relay Box:
1. Apply electrical tape to any exposed wiring to prevent future corrosion.
2. Consider using a sealant or protective spray to further protect the relay box from moisture and corrosion.
By following these steps, you can repair a corroded relay box on a 2007 Dodge Caliber SXT at a relatively low cost and restore its functionality. Always ensure electrical safety by following proper procedures and taking precautions when working with electrical components.
