Corroded or stripped
electrical ground connections can cause a loss of module communication and
other electrical system malfunctions, leading to unnecessary repairs and parts
replacement. The electrical system relies on a secure, corrosion-free ground
connection in order to function properly, so any damaged ground connections
must be repaired to provide a good mounting point with a low resistance ground
path and prevent future corrosion.
GM recently released a new bulletin covering electrical ground connection repairs. Refer to bulletin #10-08-45-001 for complete repair and installation instructions. Here are the highlights.
The bulletin outlines ground repair procedures using one of the following replacement fasteners with a conductive finish:
·
Welded M6 stud and nut (Fig. 1)
·
Welded M6 nut and bolt
·
Welded M8 nut and bolt
Before installing a new fastener in the current ground location or at a new mounting location, remove any grease from the repair area using a residue-free solvent.
After drilling the mounting hole (for a new location), remove any paint and primer from the area until bare metal is visible.
Install the appropriate new fastener and check that it is securely fastened without any detectable movement. (Fig. 2)
The M6 rivet stud will form a collar on the rear side to prevent rotation in the hole. (Fig. 3)
Cover the stud threads with protective material and refinish the repair area using an anti-corrosion primer.
TIP: The surrounding area must be properly finished prior to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground.
Thoroughly clean the stud threads using a residue-free solvent. Once dry, apply dielectric lubricant to the threads to reduce the possibility of fretting.
TIP: Fretting corrosion is a build-up of insulating, oxidized wear debris than can form when there is a small motion between electrical contacts, causing electrical resistance across the connection.
Remove any corrosion or contamination on the electrical ground wire terminal. Install the terminal, tighten the conductive nut to the proper torque and verify system operation.
Refer to the bulletin for a list of part numbers for the replacement fasteners and special tools.
A video of the ground repair procedure can be viewed on the December 2009 edition of the Emerging Issues seminar (10209.12D).
- Thanks to Dave Peacy

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