Great thread. I’m wondering if the cracked solder joint issue is more a problem with them using lead-free solder (very brittle) as oppossed to a bad soldering job. Brittle solder might be OK in some applications, but a vehicle that is vibrating and getting bumped & jarred on the road shouldn’t be one of them. I’ve run into this before with other electronics and always remove the ‘junk’ solder and re-solder using the good, flexible lead-based stuff. FWIW.

 

Wow, what a long running, active, and interesting thread! I've read all 1161 posts, and will shortly be performing the RCM fix as a "Justin Case" activity.

I bought a Crossfire Limited roadster in late October 2017, and have had no "won't start" events so far, and have a couple of questions before I implement the "RCM fix": First, has anyone had a repeat problem with their RCM after resoldering it? The first repairs seem to have been made nine years ago, and I wonder if this fix should be repeated occasionally.
Second, I plan to remove whatever solder is present and replace it with a 63-37 eutectic alloy; but I am toying with the idea of using a (higher melting temp) silver solder alloy, which should be stronger. Someone may have tried this in the last nine years.

Kudos to all who have contributed to this thread!
Rich

 

Have yet to have a return for the Mystery No Start problem once repaired.
Looks like this fixes it!

Some have been returned to have bad relays replaced once other problems arise.

 

The problems I believe are initially due to poor soldering in the manufacturers plant, stress caused by vibration and temperature was often thought to be the culprit but does not make sense. Dry joints caused the problem as can be seen using a magnifier.
Cleaning the joint and resoldering with a rosin cored electronic solder at the correct temperature is the simple answer. The problem does not have to be over over thought.
For insurance I keep a spare RCM in my trunk and spare relays at home, it is not just the solder joints that fail.

 

Thanks 180. Sent a message to tighed1 today. Believe mine to be a problem or at least I want to eliminate it as the problem. Car sputters once it goes to idle. Replaced the CPS and IC with the correct new Bosch parts already. Has 14k original and no other issues. Thanks! Mike

 

Do you still do this service? I have a 05 with the no crank problem.

 

He does.
Send him an email at tighed1@hotmail.com

 

Email received!
Thanks ala_xfire. ;-)

 

Hey all! I've got an RCM with a bad 'engine control relay #3' luckily i have a parts car i was able to rob a whole new/used RCM off of and it worked, after a new fuse. Was wondering if anybody has tracked down where to get the individual relays to solder on the board? This problem left me stranded and id like to get the single relay replace so i have a working spare RCM to keep in the trunk with the hopes ill never have to use it! Ps this forum has saved me several times and i appreciate all who contribute. You are all champions!

 

Easiest thing to do is send an email to DJ Tighe at tighed1@hotmail.com.
He will replace the relay as well as any others that need it.
It will cost you about $35, well worth it because you can only buy these relays in 10 quantity,
and it is a real ***** to replace them.

 

Hi all,


to be honest, I did not manage to read all the pages of this thread.


Just one single question: Did you find a relay that can be used as a replacement for a burnt one? One that is still on stock somehwere?


Thank you very much!




BR
André

 

The part number of the relay is in this PDF I did some years back.
CLICK
There is a minimum quantity to order it though.

 

AZ970E-1A-12D

American Zettler

40AMP Automotive Relay 12VDC coil SPST-NO

https://www.onlinecomponents.com/ame...aign=findchips

 

Ahh I see. Thank you very much.


Unfortunately they offer catastrophic conditions for shipping to Germany


BR
André

 

This relay is an industry standard so different makers are out there.
Post #1172 has the specifications for the relay.

 

You are absolutely right, thank you. So far I considered this a special type. That was wrong.



At first glance, Song Chuan 822E-1A-12VDC seems to fall off the exact same band over there in China . They just apply a different marking and put it into a different box.



I will have a deeper look in the evening.


One more question: Although quite unlikely: does anyone have a crap RCM, could remove all the components from the green PCB and could provide planar scans (i.e. not photos) from both sides?


BR

Andre

 

Back in February I asked if different (better) methods or materials had been developed for the RCM repair, and was assured that the original fix was still valid, and none of the repaired RCMs had required a repeat servicing (Thanks tighed1 and one hundred 80!). My 2005 roadster limited with 104,00 miles on it has performed without issues since I bought it in late October 2017, so I started looking for a "deal" on relays where I didn't have to buy a coffee can full of them. I finally found some in a surplus store in Albuquerque, and bought them earlier this month. Last week, I pulled the RCM out and performed the preventative maintenance of solder removal & reapplication, plus replacement of the Air Pump relay and the Fuel Pump relay, which had badly burned contacts.
For me, the hardest task was pulling the connectors out of the RCM; it felt like they hadn't been touched since the car was assembled some 13 years ago. The soldering was easy for me, because I have been soldering electronic systems and circuit boards (also copper plumbing pipes) since I was 12 years old - that was 73 years ago!
Oh, the happy ending: I reinstalled the RCM and was able to start the car! Thanks again to all who have contributed to this thread; I hope to offer helpful posts in the future - after I learn a lot more about the Crossfire!
/Rich

 

You can also source these from www.alliedelec.com with NO minimum quantity. Current price shows $2.02 USD each with very reasonable shipping fees.

 

Yesterday I was on little trip 30km from my city. I bought ice creams with my lady and after 1h XF no start.
I heared nothing, fuell pump dead, starter make not klick klack... totaly nothing, only after 5s engine fun run maximall.
I found on forum this topic, use knife and fixed RCM, car start with no problems, we back to home with smille on faces.
Now I must only renew joins.

Thank you very much tighed1 for your topic and help!

 

Mr Spider brings up a good point: if you are caught out on the road and this happens, use something sharp like a knife or your wife's tongue to poke the 3 joints a bit, just may get you home.