doje

All done with the re-wire. followed an easier path. I even completely removed the shoulders at the corners to make lazy bends in the wires. You can see it better on the second photo where I actually did it at both bends. Much easier and (IMHO) less stress on the wires. Next step is putting it back together and putting it in the car. Reporting back soon....

Original side:


Back(up) side

doje

Having taken a picture of the fuse box prior to dissection made reassembly super fast and easy. reinstalling in the car - 2 minutes once I realized I don't have to re-connect the blocks underneath (the screws pull them together for you). Now, finding what I did with the keyfob took a half hour. I had dropped it in the street. It's a miracle I found it. And now the moment you've all been waiting for....

slickstick

2005 here and think I have this same problem... debating if I am going to try and re-wire or just replace the fuse box. I would think the other wires would be next in line to break, but I don't see any complaints on here about the others which does make it seem like the one bend in particular is the issue.

slickstick

The write up simply says "replace the wire." I'm not a part time electrical engineer like you gurus, does it need to be soldered on? If not, how does it connect?

cclive

It seems like the one wire is the only one that has been a problem. A new box for hundreds of dollars will likely have the same vulnerability, so I would rather replace a ten cent wire than the whole box.

Let's remember also that this type of fuse box is probably used in all GM cars, so this is an unusual problem as we have not heard of this type of issue being a huge problem in other cars. The problem is likely limited to the one wire bend rather than the overall design of the box.

cclive

Once the box is open, you will see that those wires are just squeezed between the pins on the connector. I think that "swedged" is the right term for it. There is no soldering, although it could be done to add to the repair. Many here have added another wire between the two end points as a backup...seems like a good idea to me. I think the basic weakness is that the wire is bent too tightly at that point where it ends up breaking. It is undoubtedly made by machine, so the consistency of the problem at that one point would mean that the machine is doing something slightly wrong at that one bend.

doje

If anyone has already replaced their fuse box, or is planning to, I'd be happy to give you $50 for your old bad one.

slickstick

Well I completed the repair and everything seems to be working... Time will tell if its the long term solution! The wire wasn't visibly broken, but it did break easily near one of the connectors when I was removing it.

cclive

Good job! (And less expensive than a new box)

Dankus Z

• 111,889 2005-07 Chevy Corvettes for a potential loss of low-beam headlamp function.

This came out in a report today 5-15-2014 in Automotive News to Dealerships. They say there is a major recall on many Chevy models but for the C6 Corvette this is the only mention of any problems:


GM said a problem with the wiring to the low-beam headlamp could cause it to stop working intermittently. GM said it is aware of "several hundred complaints" but no crashes related to the flaw.

GM said 2008-13 Corvettes that have the same problem with the low beams will be fixed under a customer satisfaction program.

JRYELLOWCORVETTE

There was just a post about a Recall for just this issue. Check it out.

cclive

They are going to wait for some crashes.....

Happihank

Ive already replaced my fuse box and complained to Gm - tried to get reimbursed. so far no luck--

lght spd

Check out the link below.

They speak of recalling the 2005-07 Corvette.

About 3/4 of the page down.

http://news.msn.com/us/gm-recalls-27...on-record-pace

cclive

That sounds like an official recall..just announced today...maybe they decided not to wait for crashes...

Here's the same from USA Today:

http://www.usatoday.com/story/money/...ipers/9118137/

bonnell

Did you see this?

— Nearly 112,000 Chevy Corvettes from 2005 through 2007 because they can lose low-beam headlights. GM says when the engine is warm, an electrical housing can expand and bend a wire, causing it to fracture. GM will also repair Corvettes from 2008 through 2013 if owners have the problem.

http://news.msn.com/us/gm-recalls-27...on-record-pace

BROCKYJACK

Covered under a recently released recall I believe

BROCKYJACK

http://news.msn.com/us/gm-recalls-27...on-record-pace

EVRose

I'm wondering what their (GM) solution for repair is. Are they gonna rewire the fuse box or do they have a redesign.

cclive

I'll bet they replace it with a new one...having a mechanic rewire is probably more expensive and the quality of the repair can't be verified to be consistent across all cars.