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DIY - K40 relay resoldered joints
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Posted 11/25/2012 1:30 PM
Roly
Elite Veteran




Date registered: Apr 2006
Location: Australia
Vehicle(s): 1999 G500
Posts: 661
500
DIY - K40 relay resoldered joints

I did a search on "k40 relay" under messages and didn't find a thread specifically discussing it, so I thought that I would do one myself. The repair is noted in various places on this board, so a big thanks to all who have done it and posted here. I have had no problems with the G but just wanted to carry out some preventive maintenace to avoid being stranded. It is amazing the information here gives me so much confidence to attempt this sort of thing.
Anyway, I did the resolder today and it's straightforward, three reworked dry soldered joints and it's ok for another 10 years.

Pictures below.
Part number for the relay is A210 540 0072.



(G500 black box s.jpg)



(K40 internal relays s.jpg)



(Terminals before repair s.jpg)



(Terminals after repair s.jpg)



Attachments
----------------
Attachments G500 black box s.jpg (547KB - 29 downloads)
Attachments K40 internal relays s.jpg (589KB - 22 downloads)
Attachments Terminals before repair s.jpg (357KB - 23 downloads)
Attachments Terminals after repair s.jpg (393KB - 21 downloads)
#209170
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Author
Posted 11/25/2012 2:15 PM
koly
Elite Veteran




Date registered: Jul 2006
Location: Scottsdale, AZ USA
Vehicle(s): 2000 G500
Posts: 823
500
RE: DIY - K40 relay resoldered joints

Nicely done.
#209171 - in reply to #209170
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Author
Posted 11/25/2012 2:17 PM
DUTCH
Administrator Doppelgänger




Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2015 Audi Q7 3.0 TDI,2018 Sprinter
Posts: 9963
5000
RE: DIY - K40 relay resoldered joints

Good job!
#209172 - in reply to #209170
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Posted 11/25/2012 9:15 PM
AlanMcR
Expert




Date registered: Apr 2006
Location: US, CA, Los Altos
Vehicle(s): G300DT E300DT 230SL
Posts: 3500
2000
RE: DIY - K40 relay resoldered joints

The "before" joints were definitely on their way out, so good catch.  This board seems to be a second generation and appears to be double sided and thus most likely has through-hole plated vias.  The earlier boards were more prone to failure due to being single sided and no plating through the vias.  If you really want to make it failure-proof, solder in an L shaped bit of wire where the bottom of the L is soldered along the circuit board trace (some scraping required) and the top part of the L is soldered to the leg of the part.  Or, just replace the whole disaster with socketed relays.     
#209186 - in reply to #209170
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Author
Posted 11/29/2012 10:32 AM
koly
Elite Veteran




Date registered: Jul 2006
Location: Scottsdale, AZ USA
Vehicle(s): 2000 G500
Posts: 823
500
RE: DIY - K40 relay resoldered joints

Another DIY (from an SLK owner) with additional pix, for anyone looking for extra information (you have to create an account to see the full-sized pictures if you want to) [no association, just more info]:

http://www.gilfether.com/gallery/thumbnails.php?album=24
#209295 - in reply to #209170
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Posted 11/25/2016 5:34 AM
jmr89



Date registered: Nov 2012
Location: France
Vehicle(s): Class G W463 320Cab V6 >>Ancien 230 GE Cab 1990
100
Re: DIY - K40 relay resoldered joints

Hello
Can you for a W463 No. WDB4632501X145482 (05/09/2003) tell me if I have a K40 and where is it placed
  Thank you
#234574 - in reply to #209170
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Posted 11/25/2016 6:58 PM
Otiswesty
Administrator




Date registered: Jun 2007
Location: Portland, Oregon
Vehicle(s): 463.241, 461.213
Posts: 3013
2000
Re: DIY - K40 relay resoldered joints

If yours is 2003, then it does not have a K40 relay
http://www.vindecoderz.com/EN/check-lookup/WDB4632501X145482
#234582 - in reply to #234574
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Posted 11/26/2016 3:24 AM
jmr89



Date registered: Nov 2012
Location: France
Vehicle(s): Class G W463 320Cab V6 >>Ancien 230 GE Cab 1990
100
RE: DIY - K40 relay resoldered joints

Hello and thank you

  I see for the year2001 ?????
 
 


 
 
 




(vin.JPG)



Attachments
----------------
Attachments vin.JPG (37KB - 18 downloads)
#234584 - in reply to #209170
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Posted 11/26/2016 2:25 PM
DUTCH
Administrator Doppelgänger




Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2015 Audi Q7 3.0 TDI,2018 Sprinter
Posts: 9963
5000
RE: DIY - K40 relay resoldered joints

jmr89 - 11/26/2016 3:24 AM

Hello and thank you

  I see for the year2001 ?????


I don't know where you obtained this 2001 readout, but the delivery date for your G320 Cab is 20 Nov 2003.

You do NOT have a K40 Relay on your truck.
#234586 - in reply to #234584
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Posted 11/26/2016 5:11 PM
jmr89



Date registered: Nov 2012
Location: France
Vehicle(s): Class G W463 320Cab V6 >>Ancien 230 GE Cab 1990
100
Re: DIY - K40 relay resoldered joints

thank you very much DUTCH



It's otiswesty who posted

http://www.vindecoderz.com/EN/check-lookup/WDB4632501X145482
#234588 - in reply to #209170
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Posted 11/27/2016 8:05 AM
DUTCH
Administrator Doppelgänger




Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2015 Audi Q7 3.0 TDI,2018 Sprinter
Posts: 9963
5000
Re: DIY - K40 relay resoldered joints

jmr89 - 11/26/2016 5:11 PM

thank you very much DUTCH



It's otiswesty who posted

http://www.vindecoderz.com/EN/check-lookup/WDB4632501X145482


Since it has the year wrong and cannot properly spell Graz, I probably wouldn't put a whole lot of faith in their data.
#234591 - in reply to #234588
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Posted 11/27/2016 9:49 AM
jmr89



Date registered: Nov 2012
Location: France
Vehicle(s): Class G W463 320Cab V6 >>Ancien 230 GE Cab 1990
100
Re: DIY - K40 relay resoldered joints

It's bizard 2001 or 2003 ????
#234592 - in reply to #209170
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Posted 11/27/2016 10:29 AM
DUTCH
Administrator Doppelgänger




Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2015 Audi Q7 3.0 TDI,2018 Sprinter
Posts: 9963
5000
Re: DIY - K40 relay resoldered joints

jmr89 - 11/27/2016 9:49 AM

It's bizard 2001 or 2003 ????


The Vehicle Data Card on the Daimler EPC.net website says that first delivery was 20 Nov 2003.
#234593 - in reply to #234592
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Posted 11/27/2016 10:36 AM
jmr89



Date registered: Nov 2012
Location: France
Vehicle(s): Class G W463 320Cab V6 >>Ancien 230 GE Cab 1990
100
Re: DIY - K40 relay resoldered joints

It's very bizarre on the gray card 1st registration: 05/09/2003
#234594 - in reply to #209170
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Posted 12/5/2019 11:24 PM
G4Garret
Veteran




Date registered: Apr 2006
Location: Oak Ridge - Knoxville - Windrock Tennessee
Vehicle(s): 2000 G500, U1100, SLK350, LR 101, WC-63 6x6
Posts: 243
100
RE: DIY - K40 relay resoldered joints

I did a write-up on this back in 2006, roughly, but perhaps it is stuck over on the other forum.

Anyway, I've found you can improve the reliability of the K40 relay re-solder by reinforcing the solder joints with small pieces of copper braid. Solder-wick makes a convenient way to do this. It's like putting fiberglass reinforcement in a resin, more or less. I think I had photos when I did that write-up. I'll see if I can find them.

Garret
#241300 - in reply to #209170
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