If you’re currently experiencing TIPM (Totally Integrated Power Module) issues or have dealt with them in the past, you know just how frustrating and disruptive it can be. For many, the first sign of a failing TIPM is the failure of the fuel pump relay. Unfortunately, this is often just the beginning, as other relays within the module begin to fail as well. The TIPM’s reputation for fuel pump relay failures has led to a slew of aftermarket solutions, but not all of them are as reliable as they may seem.

The Temporary Fix Trap: Aftermarket Bypass Kits

A quick search online will reveal a wide variety of aftermarket DIY solutions, such as bypass kits, that promise to resolve TIPM problems. However, these kits are typically just temporary patches for a much larger issue—the failing relays in the TIPM. While a bypass kit might buy you some time, it will not address the root cause of the problem and can potentially lead to more severe issues down the road.

Solid State Relays: The Not-So-Ideal Replacement

In response to this, some TIPM remanufacturers or rebuilders have attempted to “replace” traditional relays with solid-state relays (SSRs). These relays, unlike their mechanical counterparts, do not have physical moving contacts. On paper, the idea of using a switching device without moving parts may seem like a smarter, more durable solution. After all, SSRs are known for being more reliable and long-lasting in certain applications. However, when it comes to TIPM circuits, this approach has significant drawbacks.

Let’s break down why replacing mechanical relays with solid-state relays in TIPMs is not as straightforward as it may appear:

1. Handling High Starting Currents and Back EMF

Motors, especially in systems like fuel pumps, require a high starting current to get going. As these motors operate, they also generate back electromotive force (back EMF)—an unwanted electrical surge that can cause instability in the system. Traditional mechanical relays are designed to handle both high current and back EMF with ease. Unfortunately, solid-state relays struggle in these areas. If not carefully managed, an SSR can overheat or fail prematurely when exposed to these high loads, leading to catastrophic failure.

2. The Risk of Voltage Drop and Overheating

Unlike mechanical relays that are either fully “on” or “off,” solid-state relays are often designed to operate with varying levels of resistance. This can be problematic, especially when the circuitry driving the SSR is not specifically designed for such variability. If the design isn’t perfect, it can result in voltage drop, overheating, and, ultimately, an unreliable system. Mechanical relays, on the other hand, have no such issues since they are either completely engaged or disengaged with no intermediate states to cause unwanted resistance.

3. Potential for SSR to Get Stuck “On”

One of the more dangerous aspects of replacing a mechanical relay with an SSR in a TIPM is the possibility of the solid-state relay becoming stuck “on.” This occurs when the driving circuitry is not properly isolated from the other relays in the system. When other relays, such as the regular mechanical relays, generate back EMF, it can seep into the SSR circuit, causing it to malfunction. This can result in the SSR staying in the “on” position indefinitely, causing a range of other electrical issues in the TIPM.

Why Replacing Relays Isn’t Always the Answer

As you can see, there are several technical reasons why bypassing or re-engineering the TIPM relay system is not a wise decision. Even some TIPMs that were originally designed by the manufacturer to use solid-state relays end up failing precisely BECAUSE of this choice. Simply put, replacing mechanical relays with solid-state alternatives is not a guaranteed fix. In fact, in many cases, it can exacerbate the issue, leading to more expensive repairs and even further damage to the TIPM board or other components.

The Dangers of Unvetted Aftermarket Solutions

Here’s a real-world example: A TIPM came into our facility for repair after an aftermarket relay solution had been installed. As you can see from the images, the damage was severe. What was meant to be a quick fix turned into a costly repair, with potential for even more damage if left unaddressed. This type of failure can not only harm the TIPM itself but also affect other critical components, leading to a cascade of problems that could leave your vehicle inoperable.

Other TIPM remanufacturers often attempt similar unproven solutions in an effort to differentiate themselves in the market. However, as we have seen time and time again, these so-called "fixes" rarely solve the underlying issues and can often lead to worse outcomes for the customer. These quick fixes may seem appealing in the short term, but when it comes to something as crucial as your vehicle’s electrical system, it's essential to invest in long-term, effective solutions.

The Better Solution: Remanufacturing With Proven Components

At Circuit Board Medics, we take a different approach with our  TIPM Exchange and Repair Services. Rather than relying on unproven aftermarket parts or risky fixes, we focus on remanufacturing your TIPM with components it was designed to operate with. We do not just fix the immediate issue; we upgrade the components to ensure that future problems do not occur. Our goal is to provide a solution that not only addresses your current issues but also increases the longevity and reliability of your TIPM, saving you from costly repairs down the road.

When you choose to work with us, you can rest assured that we take your business seriously. We believe in providing high-quality, reliable repairs, and we would not risk attempting an untested fix on a critical component like your TIPM. After all, your safety and satisfaction are our top priorities.

Wrapping Up

If you're dealing with TIPM issues and are considering an aftermarket solution, it is essential to understand the risks involved. While bypass kits and solid-state relay replacements might seem like quick fixes, they often lead to more significant problems in the long run. The better solution is to remanufacture your TIPM with high-quality, upgraded components that will not only fix your current issues but also help prevent future failures.

If you are in need of a reliable, high-quality rebuilt TIPM, we have got you covered. Click the link below to find your exact part, and explore our repair-and-return or exchange options. And if you have any questions, do not hesitate to give us a call or send a text—we are here to help.