DaveB! What a fine picture of your DME relay. It looks the same as mine when I pulled the can off. What strucks me when I see your relay is that you point out, is the wires from relay frame to relay yoke, they seem to be welded differently to the other left relay, more heath I think. Also, they seem to be too short for the yoke to move all the way down against the coil and the contacts they are supposed to close. I think it should be a distinct
bow of the flexible wire between relay frame and relay yoke thereby making yoke more easily attracted to the coil when operated that part of DME-relay.
BTW, relay looks good and I would suggest you to polish or rub the contacts with fine sandpaper and clean them with alcohol. And WERY important, operate the relay coils with a battery charger (more than 12V) many times and look at the relay moving parts...do the close as supposed to? Check the ohmic resistance over contacts with a volt/ohm/ampere meter when closed. It shouldn´t be more than 0,4 ohms (resistance from metering wires). If you have this you are fine. But I cant recommend to lubricate the yokes with oil as relay part become hot and oil will probably evaporizise to the contacts......not good. Perhaps a small amount of hot resistant grease will do.
For the time beeing I keep my DME-relay in the glove box and run the car with a common available double relay 2x30 Amp wired exactly as the original one. Works just fine during 2000 km this summer. Only luke warm after a 100 km run as an example. Now I´m going to modify the DME again to a single coil relay with double throw contacts 2x30 Amps with same security of function as original.
Sorry for all the words but I´m having the flu and I´m bored to death and my fingers were itching to write this
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Lapponia 1984 944 na