I had exactly the same thing on my 99 Caravan. First the relay went and the dealer replaced. Fortunately my relay shorted so the fan ran all the time so no overheating occurred. Then it quit again and the dealer found the socket was melted. I think either one of two things is happening;
1. The socket is under-designed for the current it must carry in the heated environment it is in and the contacts lose tension and arc.
2. The socket gets damaged if the replacement relay is not seated properly in the socket. My dealer replaced the socket and charged me only for materials, no labor. So I think they know there is a problem here. Arcing in the socket would soon send heat up the metal contacts into the relay and destroy it.
Thursday, May 15th, 2008 AT 7:57 PM