[35charlie]

I just replaced mine last night also in about 10-15 minutes. I found it was simple enough to just drill two 1/2" holes about 2" apart above the screws holding the relay. You can touch the relay by reaching through the large hole in the back of the housing so determining where to drill isn't hard. If you miss a little you can egg the holes easily with the drill.

Once the holes were drilled, I used a socket + extension to reach the screws. I reached in from the back and grabbed the upper screw as I removed it. Since I could not reach the lower one, I put a blob of grease into the socket so the screw stuck to it as I pulled it out.

Once the screws were out I fished the relay up through the large hole in the back. To release the connector, pull the red tab back a bit then press on the black release tab back near where the wires attach while gently pulling the relay out.

Reassembly was just the reverse including the grease in the socket.

I didn't bother plugging the holes because that whole area hardly seems waterproof anyway and I doubt a little water would hurt much. Plus the holes I drilled weren't into the gutter part of the plastic. If water is a concern it would be simple enough to dab some sealer in to block 1/2" holes. The other reason I didn't bother is now it's a 5 minute job and $35 part even if it fails again.

One pitfall I ran into: The headlight assembly is held in by the long screw plus 2 press in posts. The lower inside post would not go back into place so when I checked I realized the yellow plastic insert had come out of the housing and was stuck on the post on the back of the headlight. I pulled it off and put it back into the housing and all was well. I notice the guy in the link posted above appears to have the post broken off the headlight and stuck in that same insert so obviously someone forced that one a bit.