Adams' Apple said: Glad you found something, Gary!! Wow...what an ordeal, eh? I would suggest you try to find a new relay....those things will get hot inside, and start melting the Bakelite insulator on the bottom. That may be the real problem...the connections on the inside may be failing. You can pull the metal cover off and have a look-see, if you want...just to see if it is in the process of melting or not. If it looks good inside, then cleaning the terminals of the connector might be all ya need. You could also smell the bottom of the relay...if it smells like nasty melted plastic, I'd start looking for a replacement.