this is a farely common problem with aftermarket relays. do not see it much with the ford relays. what happens is that when you turn the key to the start position the relay is activated. now these things have alot of current going through them. what happens is when the contact plates inside contact each other they cause a pretty large arc. over time the plates will eventually stick together due to the extreme heat that runs through that relay. my reccomendation is to fork over the cash for a good ford relay and that should take care of your problem.
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