Strarter Relay
#1
Starter Relay
Location of the 5 pronged starter relay switch on the 2007 H3?
Starter is starting to click without engaging occasionally, and continue engaging after the key is released - occasionally as well.
Planned to swap the relay switch first, then the starter if need be. I'll approach other issues if the problems still persist.
Starter is starting to click without engaging occasionally, and continue engaging after the key is released - occasionally as well.
Planned to swap the relay switch first, then the starter if need be. I'll approach other issues if the problems still persist.
Last edited by Tomahawk; 07-06-2012 at 01:21 PM.
#5
wiring diagram shows #85 (30amp fuse)
77 (pcm) & 78 relay(run/crank)
(page 2 below)
http://achim1000.bplaced.net/hummerf...ELECTRICAL.pdf
swap the 78 with the 87, try for a few days, if all is normal, change the relay.
TSB 09-06-03-004
2005-09
All Vehicles - Diagnosing and repairing fretting corrosion
Do this--- Disconnect affected connector and apply lube
Dont do this--- Don't replace modules without duplicating condition
09-06-03-004
Fretting corrosion is a buildup of insulating oxidized debris (nonconductive material) caused by micro motion between two contact surfaces. (Fig 1)
It's commonly found on tin plated terminals, such as Micro pack 100 and Micro pack 64 connections.
Past Serviceability Issues
Replacement of sensors, modules and other components will result in only a temporary relief of a fretting issue. Actually, just the cycling of a connector will clear the fretting corrosion from the terminal, correcting the condition for a short time until fretting corrosion builds back up again.
Typical issues caused by fretting corrosion include:
- Intermittent electrical component operations
- DTCs being set, or No Trouble Found (NTF)
- Low current signal circuits -- fretting corrosion (high resistance) can cause intermittent connections
- High current power circuits -- permanent increases in the connection resistance can lead to overheating
Evidence of Fretting
Fretting usually appears as:
- small, dark smudges on electrical terminals
- smudges at the locations of electrical contact (Fig. 2)
In less severe cases, it may require a magnifying glass to identify a fretting condition.
Causes of Fretting
Fretting is caused by the motion between the connector and the terminal, which can be due to:
- Vibration - micro motion between two contact surfaces causing build up of insulating oxidized debris (nonconductive material)
- Thermal cycling
- Packaging of the connector, wiring harness and/or device
- Poor connection/terminal retention
With continued microscopic fretting, enough insulating tin-oxide wear debris can build up high resistance creating intermittent connections. (Fig. 6)
Service Solution
Disconnecting and reconnecting a connector will temporarily "fix" a fretting condition, but it will eventually come back if the conditions for fretting still exist. The best preventative measure is to perform the following:
1. Disconnect the appropriate module(s)/connector(s)
2. Lube both sides of the connector (module side and harness side) with NyoGel 760G lubricant, GM part number 12377900 (in Canada, P/N 10953529)
3. Reconnect the connector
4. Wipe away any excess lubricant
5. Duplicate the condition per the SI Diagnostic Procedure Instruction section
- Circuit/System Description
- Conditions for Running/Setting the DTC
- Circuit/System Verification
IMPORTANT: If the condition CANNOT be duplicated, the repair is complete. DO NOT replace the module/component/part.
77 (pcm) & 78 relay(run/crank)
(page 2 below)
http://achim1000.bplaced.net/hummerf...ELECTRICAL.pdf
swap the 78 with the 87, try for a few days, if all is normal, change the relay.
TSB 09-06-03-004
2005-09
All Vehicles - Diagnosing and repairing fretting corrosion
Do this--- Disconnect affected connector and apply lube
Dont do this--- Don't replace modules without duplicating condition
09-06-03-004
Fretting corrosion is a buildup of insulating oxidized debris (nonconductive material) caused by micro motion between two contact surfaces. (Fig 1)
It's commonly found on tin plated terminals, such as Micro pack 100 and Micro pack 64 connections.
Past Serviceability Issues
Replacement of sensors, modules and other components will result in only a temporary relief of a fretting issue. Actually, just the cycling of a connector will clear the fretting corrosion from the terminal, correcting the condition for a short time until fretting corrosion builds back up again.
Typical issues caused by fretting corrosion include:
- Intermittent electrical component operations
- DTCs being set, or No Trouble Found (NTF)
- Low current signal circuits -- fretting corrosion (high resistance) can cause intermittent connections
- High current power circuits -- permanent increases in the connection resistance can lead to overheating
Evidence of Fretting
Fretting usually appears as:
- small, dark smudges on electrical terminals
- smudges at the locations of electrical contact (Fig. 2)
In less severe cases, it may require a magnifying glass to identify a fretting condition.
Causes of Fretting
Fretting is caused by the motion between the connector and the terminal, which can be due to:
- Vibration - micro motion between two contact surfaces causing build up of insulating oxidized debris (nonconductive material)
- Thermal cycling
- Packaging of the connector, wiring harness and/or device
- Poor connection/terminal retention
With continued microscopic fretting, enough insulating tin-oxide wear debris can build up high resistance creating intermittent connections. (Fig. 6)
Service Solution
Disconnecting and reconnecting a connector will temporarily "fix" a fretting condition, but it will eventually come back if the conditions for fretting still exist. The best preventative measure is to perform the following:
1. Disconnect the appropriate module(s)/connector(s)
2. Lube both sides of the connector (module side and harness side) with NyoGel 760G lubricant, GM part number 12377900 (in Canada, P/N 10953529)
3. Reconnect the connector
4. Wipe away any excess lubricant
5. Duplicate the condition per the SI Diagnostic Procedure Instruction section
- Circuit/System Description
- Conditions for Running/Setting the DTC
- Circuit/System Verification
IMPORTANT: If the condition CANNOT be duplicated, the repair is complete. DO NOT replace the module/component/part.
Last edited by hummerz; 07-31-2012 at 02:46 PM.
#9
Fuse 84 is for your trailer harness.
Check the trailer wire harness behind the rear bumper where they attach the harness to the frame.
Look between the rear bumper (near the license plate) and the rear door (when open). There is a wire harness there tat rubs against the frame. Find that section and remove all of the tape and coverings. Repair the frayed or broken wire! Do not reattach to the frame, let the harness hang after to shrink wrap and tape the harness.
Check the trailer wire harness behind the rear bumper where they attach the harness to the frame.
Look between the rear bumper (near the license plate) and the rear door (when open). There is a wire harness there tat rubs against the frame. Find that section and remove all of the tape and coverings. Repair the frayed or broken wire! Do not reattach to the frame, let the harness hang after to shrink wrap and tape the harness.
#10
Do you have a trailer hitch with the trailer wiring plug? If so, open the cover of the trailer wiring plug and clean it out and then spray electrical contact cleaner in there.
The Key is stuck = GM's way of telling you your battery is dead.
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