What to Do If the Car Fan Relay Keeps Burning Out?

[AbigailAnn]

Check the load type, whether it is a capacitive load, resistive load, or motor load. Different loads require different multiples for SSR selection. Installation environment has a significant impact. Without proper heat dissipation and ventilation, electronic components are prone to burning out.

[Clyde]

Ah, this issue reminds me of a similar situation I encountered when helping a friend fix their car. The fan relay keeps burning out, and the root cause is often excessive current or a short circuit. We need to troubleshoot step by step: first, check if the relay itself is of poor quality—aged contacts can melt when overheated. Then, inspect the fan circuit for poor connections, such as exposed wires or loose plugs. Additionally, voltage issues are critical; if the alternator outputs too high a voltage, it can burn out the relay, so use a voltmeter to check for stability. A stuck or immobile fan can also increase the load and trigger burnout. I recommend replacing it with an OEM or high-quality relay and conducting a thorough inspection of the fan system and wiring connections to address the root cause, not just the symptoms. Ignoring this long-term can affect cooling, and engine overheating could lead to bigger trouble—better to resolve it early for peace of mind.