[Healeys] Replacement of Turn Signal Relay.

Sun Mar 22 12:06:36 MDT 2026

Hi Michael,

Thank you so much. Your method for removing and reinstalling the relay is 
brilliant.

Unfortunately, I didn't come up with this promising solution. Simply so 
easy, fantastic.

Thanks! 

Josef Eckert

Königswinter / Germany

-----Original-Nachricht-----

Betreff: Re: Replacement of Turn Signal Relay.

Datum: 2026-03-22T17:28:44+0100

Von: "Michael Salter" <michaelsalter at gmail.com>

An: "josef-eckert at t-online.de" <josef-eckert at t-online.de>

You are absolutely correct josef. 
This is my trick. Remove the left front wheel and find the weld-nut for 
that screw.
Carefully grind off the end of the screw to the level of the weld-nut then, 
very carefully, starting with a 1/16" dbit, drill out the 10/32 screw 
without damaging the weld-nut too much.
This will release the top of the relay. Run a 10/32 tap through the 
weld-nut then take out the 2 lower screws and tackle the 8 terminal screws.
Back in the day the relays weren't that expensive and we used to just 
replace them when they were thought to be faulty however, I gathered up the 
removed ones in a bin.
Last week, after the problems that I had with my second cheapo repo, I 
pulled 5 of them out of the bin and checked them.
The biggest problem was getting the slot cheese head terminal screws out 
without breaking them but a little carefully applied heat solved that.
Once I removed the covers and cleaned up the 8 terminals I was amazed that 
every one, after a couple of very minor adjustments, could be made to work 
perfectly.
Not one of the coils, the component that I had always suspected was the 
most likely point of failure, had any sort of problem.
I now have 5 fully functional turn signal relays that I'm in the process of 
refinishing.
Getting that top screw in will still be difficult but it can be done before 
refitting the cover.

M

On Sun, Mar 22, 2026 at 7:48 AM josef-eckert at t-online.de
<mailto:josef-eckert at t-online.de> <josef-eckert at t-online.de
<mailto:josef-eckert at t-online.de> > wrote:

  Michael,
  Since it's almost the same topic, but what bothers me much more is
  replacing the relays on the 6-cylinder Austin-Healeys.
  The top screw that holds the relay is inaccessible with a screwdriver
  when the cold air duct is installed. The same goes for
  the upper cable clamps. Is there a trick to removing the faulty turn
  signal relay and installing a replacement without removing
  the cold air duct and potentially damaging or crumpling it?
  Thank you for any helpful suggestions.

  Josef Eckert 
  Königswinter/Germany

  -----Original-Nachricht-----

  Betreff: Re: [Healeys] Replacement Turn Signal Relay.

  Datum: 2026-03-22T12:33:37+0100

  Von: "simon.lachlan--- via Healeys" <healeys at autox.team.net
  <mailto:healeys at autox.team.net> >

  An: "Michael Salter" <michaelsalter at gmail.com
  <mailto:michaelsalter at gmail.com> >, "healeys at autox.team.net
  <mailto:healeys at autox.team.net> " <healeys at autox.team.net
  <mailto:healeys at autox.team.net> >

  Regarding these contraptions, there is a third way. I've mentioned it to
  M before....one can gut the old relay and rebuild its internals with new,
  modern, relays. I've done two or three. The first because my original had
  gone into terminal decay and the others because I'd bought clapped out
  originals at a boot fair. Anyhow, the first one's been in the car for
  some years now and works fine. The others are in one of the "boxes of
  useful things I may need one day". I've done the same to overdrive
  relays. By the way, I don't claim to be the first person to have done
  this!!
  Simon

  ----------------------------------------------------------------------
  From: Healeys <healeys-bounces at autox.team.net
  <mailto:healeys-bounces at autox.team.net> > on behalf of Michael Salter <
  michaelsalter at gmail.com <mailto:michaelsalter at gmail.com> >
  Sent: 20 March 2026 16:23
  To: healeys at autox.team.net <mailto:healeys at autox.team.net> <
  healeys at autox.team.net <mailto:healeys at autox.team.net> >
  Subject: [Healeys] Replacement Turn Signal Relay.

  All Big Healeys prior to the later Phase 2 BJ8 use a Lusas 33117 relay
  for the turn signals. This relay connects the appropriate lamps to the
  turn signal flasher unit, overriding the brake light switch on turns.
  These Lucas relays were a very primitive (by today's standards) but very
  robust unit and could withstand a short circuit as often happens with the
  glass lens type 594 turn/side/brake lamps used on these models at least
  until the fuse blew.
  Within these lamps it is very easy to produce a short to ground.
  Over the last few years replacements for these relays have been provided,
  under the Lucas name and the same 33117 part number, which have been
  completely redesigned and incorporate 2 modern G2R-1-E relays. 
  I have purchased 2 of these modern style relays and both have failed
  because the  G2R-1-E relay relays don't seem to be anywhere near as
  robust as the originals and fail before the 35 amp fuse can protect them.

  So, a word of caution, if you are using one of these (improved) cheapo
  repo turn signal relays, be very careful to avoid short circuits in the
  turn/brake/side lamps.
  The attached pics are of the original type and the circuit board from the
  "improved" replacement.

  M 
  [image.png]
  [image.png]

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