Heading for work one morning, my C5 Corvette (1997-2004) ran terrible. When I headed home, it behaved the same way. The next day it wouldn’t do anything but flash the dash lights when I attempted to start it. The car has a self diagnostic system that can be accessed by pushing the correct display buttons, but this didn't work either.
Fortunately, I knew about an Internet forum for Corvettes that's loaded with all kinds of information, especially on fixing problems.
This forum is very helpful for those owners who are far from large cities, since small dealerships don’t sell many Corvettes, and consequently, their service technicians are not experienced with these vehicles. The forum included several stories of technicians simply “throwing parts” at a problem, hoping that the bad component ended up getting replaced. Meanwhile, the owner pays for everything, and the replacement parts are very expensive.
There is one service technician who participates on the forum who has a great deal of experience with Corvettes. He suggested that I remove the ignition switch, take the unit apart, and look for bad electrical contacts inside. He also provided a link to a previous post of his in which he provided step-by-step disassembly instructions, a repair procedure, and photographs.
Sure enough, after I disassembled the switch, I found that two of the five electrical contacts were coated with a black substance, while a third was one-quarter coated. After careful “sanding” with 2000 grit paper and an alcohol cleaning, I re-assembled the switch and everything started and behaved as normal. So, what could have been a repair bill close to $1,000 was fixed at no cost, in an hour.
This entry was submitted by Bob Salter and edited by Rob Spiegel.
Bob Salter is a mechanical engineer who works for American Roller Bearing Company. He is also a dedicated do-it-yourselfer.
Tell us your experience in solving a knotty engineering problem. Send stories to Rob Spiegel for Sherlock Ohms.
One thing that I learned with this episode is that the modern computer controlled automobiles are sometimes very difficult to troubleshoot. Sure, one can push some buttons on the Corvette's dash to troubleshoot, which is more than one can do with most newer automobiles, but other maladies can prevent the system from working. Bad ground connections, usually from corrosion, and low battery voltage can often disable the computers. These were checked first. In my case, the two computers, Power Control Module (PCM) and Body Control Module (BCM) seemed to have enough voltage to operate a relay (clicking sound) and flash the dash lights, in sync. However the BCM didn't have the ability to read the resistance of the pellet in the key to satisfy the security system. But, a couple times it did as the engine would crank but not fire. Each GM dealership should have a diagnostic computer called a Tech II for trouble shooting, but this is still no guarrantee of identifying the root cause of the problem. The gentlman that helped myself and others is a GM certified technician, and the way he identified the problem was experience. He recommended that a previous Corvette owner with the same problem replace the ignition switch on a hunch, which solved this owner's problem. He was good enough to send the faulty switch to the technician, who disassembled it, observed the contacts, and figured out how to fix them. My good fortune is that he shared this insight on the forum. This epsisode reinforces my long time theory that experience in auto repair is the best diagnostic tool.
The potential $1,000 figure quoted in the article is probably not very far off. Having the ability to do the repairs yourself is huge, given the cost of parts on many of today's vehicles. Even more so on the 'Vette, which, according to Consumer Reports, has only an average reliability rating for models between 2006 and 2011.
Love your story Bob. I too do a lot of my own car repairs (I own a 33-year-old car). Usually, whatever repair I need to do has been done by someone else who has posted step-by-step instructions, often with a video. This Internet thing is great. I hope it sticks around.
I have to agree with comments so far – Mechanics often play it safe, and replace parts – not to intentionally run up the bill (as my Wife speculates) – but, because they can't find the real root cause issue; and then they justify it with statements like, "well, that element had a lot of corrosion, and would have need replacing SOON, anyway -so- better safe than sorry". The much more frugal side of me has often frequented On-line blogs and boards to find better clues.
Bob, it is very common for auto mechanics to "throw parts" at a problem. Actually, I found when I was working on my own cars (typically old British sports cars), I did it myself, since they were not easy to diagnose. That is why we often collected old cars and parts, so it generally did not cost a lot. We also did not have the on-line forums.
From Dell / Intel® New Paradigms in Design Work Scott Hamilton, vertical market strategist for Dell Precision workstations, 5/2/2013 5
Early in my career, I worked as a draftsman and remember the days of drawing on vellum with numbered pencils and Mylar with plastic lead. This was a fun experience in the sense that I ...
I've been using workstations for more than 10 years and love finding ways to get more performance from my system. With demanding professional applications that require more power each ...
A lasting memory from my first job as an engineer in an auto assembly plant is standing on hard concrete at six in the morning, vending-machine coffee clutched in hand, listening to ...
For industrial control applications, or even a simple assembly line, that machine can go almost 24/7 without a break. But what happens when the task is a little more complex? That’s where the “smart” machine would come in. The smart machine is one that has some simple (or complex in some cases) processing capability to be able to adapt to changing conditions. Such machines are suited for a host of applications, including automotive, aerospace, defense, medical, computers and electronics, telecommunications, consumer goods, and so on. This radio show will show what’s possible with smart machines, and what tradeoffs need to be made to implement such a solution.
To save this item to your list of favorite Design News content so you can find it later in your Profile page, click the "Save It" button next to the item.
If you found this interesting or useful, please use the links to the services below to share it with other readers. You will need a free account with each service to share an item via that service.
Tweet This
11 
