My fuel pump relay is wearing out every few months causing the Jeep to die suddenly or not run. I don't want to be replacing it 4 times a year. I also want to trust my Jeep on the trail without risking being stranded in the wilderness.
What could be causing the apparent extra wear on the relay? Is that just a symptom, or the cause? Have you had this issue?
ALL THE BACKSTORY:
Purchased the Jeep last November and it ran just fine. Several months down the road the engine wouldn't start smoothly every time. Occasionally needed two or three cranks to fire. Within 10 days it worsened to the point of dying while driving if I hit a bump or jostled it too much. (That's not good for an off-road vehicle.)
IN THE SHOP:
I had it towed to the shop because it finally wouldn't start at all. guys discovered a weak/dirty connection in the wires at the fuel pump. They cleaned it up and snapped it all back together. No charge, all was good.
One month down the road the same issue began occurring, and just like last time the severity increased slowly. It left me stranded a block from the office on the way home one night. Hesitant to tow it back to the shop I jiggled the "problem" wires from last time with no results. I learned to switch the horn relay and test for pump pressure near the engine. No fuel was making it to the engine, until I swapped the relays and the Jeep started fine. (of course, now the horn wouldn't work)
YESTERDAY: The engine died right after startup. I restarted with no problem, but by the end of the day it was taking three cranks just to run. This morning it just quit a block from home. I was desperately late already, and after five cranks was thankfully off and running to my meeting. After the meeting it wouldn't fire at all. There was no fuel at the engine. I swapped the relays, and it started fine. Oddly, the horn works too.
I have checked and cleaned the connection wires, they seem fine.
I do have a new pump on the self I can install, but have really hoped to avoid dropping the tank if that's not the issue.