SOME 05/06 Fuse Boxes, Engine compartment, have had wire failure causing the SSR to "quit" while driving.
Some have experienced SSR running for 40 minutes or so and then "quit" only to cool and restart.
This problem eluded GM Engineers or they were not interested.
Our Art Bonadies aka abonadies and Marty aka Phantom Guy, Florida Chapter, found the problem by simulating conditions of the fuse box in a lab setting. As engine heat rose, the rear left quadrant of the fuse box dropped from 12 volts to 3, yes 3 volts.
Engine "quit" fuel injectors "quit" staring "quit" etc.
Art and Marty traced the problem, with use of oscilloscope, to a broken wire that provides power to the back left quadrant. One wire at a bend, was "pressed" down so hard during production that the wire was very thin.
Art and Marty then applied "HEAT" to the wire and sure enough it separated enough to shut down that quadrant. When wire cooled it made enough contact to operate the quadrant again. So as your engine compartment and fuse box become "Hot" the wire separates.
Their finding determined that when current was applied to the "thin" area of the wire it would expand and then contract, until it failed. But failure was not permanent it was intermittent depending on heat. As engine/fuse box cooled, wire would reconnect enough to return operation to "normal".
1. IF your R has never had a problem, then it may never have a problem, but if one develops, at least you will know what it is and how to fix it.
It was apparently a "PRODUCTION RUN" that was not set right on "Down Pressure" for the wire insert. When? How many? What serial numbers? Don't Know!
2. GM can replace engine fuse box. Cost about $700 bucks plus labor. NO guaranty it won't have a bad wire.
3. BEST option, if you are experiencing a problem, send your Fuse Box to Art Bonadies for wire replacement and re-routing.
Art is doing "Quick" turn around repair and for only $100 bucks plus shipping.
"special wire and wire size in the fuse box".
Contact Art aka abonadies for more information.
Check Tech Discussions/SSR How to Library for pictures and more information on the wire problem.
Here is link: https://onedrive.live.com/?cid=3ef39...5ADCE5E5%21853
1. Where wire breaks
2. Repaired fuse box wire, NO bends.