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Old 20th April 2013, 07:47 AM   #11
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If it happens to be just the caps, a few things that I can think of that could exacerbate the possible thermal issues. First off, are the old caps 85oC or 105oC, if 85oC rated that is likely a huge part of the problem. 85oC rated caps tend to be MUCH more sensitive to heat than the 105oC rated ones. Second, there is a good chance these caps are getting the heck thrashed out of them (they have to handle large currents AND the noise from the automotive charging system). It looks like the board uses SamYoung capacitors. A Korean company, unfortunately I have seen these fail in the past. I can't see what the models are for the caps. In image search I just saw an SHL (which are 85oC parts). I would recommend some better parts but without the model number I can't tell height of the caps.
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Old 20th April 2013, 12:19 PM   #12
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The height is 30mm, even a 35mm would work. I might just replace mine with nichicon HE or Panasonic FC both are 105c & designed for power supplies.
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Old 20th April 2013, 11:47 PM   #13
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I changed all mine to nichicon, from digikey.

Not sure why the caps got this way, My guess is he beat the hell out of it until it just couldnt do it anymore.
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Old 20th April 2013, 11:52 PM   #14
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I might do mine, I'll use nichicon HE caps, they have a long life and 105c rating.
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