On my 1986 fiero se the passenger side headlight relay keeps clicking and then when the knob is turned and the switch engages it stops clicking. The motor was rebuilt cause the light wouldn't go down and it still clicks. it does go down now though. But, why does it keep clicking even when the headlights and car are off? Do i need a new relay? Gonna interchange the relays later, but just thought you guys
might have some input.

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Unconditional Surrender

Are you sure it's the relay that's clicking and not the limit switch? Is the knob on top twitching when it clicks?

yeah its the relay, it keeps clicking and then you turn the knob slightly and the limit switch clicks, then the relay doesn't click anymore

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Unconditional Surrender

A common cause of that is that the rubber weather seal underneath the knob often slides up underneath the knob when reassembling. This is especially true for anyone who's rebuilding their motors for the first time. Another cause can be that when you slid the limiter switch back into the housing, one of the brushes caught the commutator and popped off. The motor can't develop enough speed or torque to fully open the points.

If you find that it isn't the relays, you'll need to remove the headlight assembly and look underneath the motor to see if the rubber seal is down into the top of the housing or just sitting on top. In the meantime, unplug the single blue wire connector to prevent damage to the motor or draining the battery.

interchanged the relays and that solved the problem, gonna go to auto value for a new one tomorrow

Thanks for the input

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Unconditional Surrender