Q. I'm curious.
With all the odd problems you help people with, what the
most difficult to fix or unusual problem is you've ever
encountered?
A. There have certainly been many of
them — some involved symptoms that defied reason,
relative to the fix that resolved them. Others were
really difficult and required an embarrassingly lengthy
amount of time to resolve, or I failed to diagnose it
right the first time and the car came back. Some of the
problems that come in from readers certainly fall into
the unusual category, but unless one is directly
involved in the diagnosis and hands-on repair that fixes
it, it's hard to know for sure how everything plays out.
My weirdest problem was 20 years back,
during the winter, on a brand new Pontiac Bonneville.
Our customer complained the CD player seemed to have a
mind of its own, occasionally changing tracks, varying
the volume, etc. The car was one of the very first, I
believe, to have steering wheel control buttons for the
radio and heater/air conditioner. After driving the car
many times and perhaps once verifying the maddeningly
infrequent demon, I tested, measured, and did my best to
figure out why this could be happening, without success.
Next, I followed Pontiac's advice by sequentially
swapped the CD unit, steering wheel unit (a very
expensive and complicated control device), translator
module, turn signal switch, and all related wiring
harnesses with an identical unsold new car. The problem
would still occur, maybe once or twice at best, after
driving the car for several hours under every imaginable
condition (fast, slow, turning sharply, under power
lines, over bumpy roads, and while operating other
equipment)
The car had now been back to us
perhaps three times — a very embarrassing situation
— and my second call to Pontiac for technical
assistance resulted in an engineer being dispatched, to
arrive the following week. With one final idea up my
sleeve- hoping to salvage my pride before the engineer
arrived— I asked the customer to bring the car in once
again (the idea would have proved fruitless, had I
ultimately employed it). As I drove him home, I noticed
he had opened the sunroof — he said it was his first
and he loved using it, even in winter. As we neared his
home, driving up a tree lined street/driveway, the CD
player went nuts. We turned around and drove the street
again, with similar results. Then it hit me! I closed
the sunroof, we repeated the circuit several times, and
the symptoms completely vanished. I opened the sunroof,
re-encountered the symptoms, and fixed them by laying a
cloth over the steering column/steering wheel
intersection. Yikes! The rapid pulses of light/darkness
caused by the sun and trees, time of day, open sunroof,
at just the right frequency, was sneaking into the
steering column, confusing the optical coupling inside.
The back of the steering wheel contained several light
transmitters (similar to a TV remote control) and the
turn signal switch held several photo transistors.
However the steering wheel might be turned, at least one
of the optical couplings would always handshake. This
clever but problematic system was soon abandoned, with
the implementation of air bags, as the air bag clock
spring allows a more sure connection between steering
wheel buttons and the stationary steering column. The
engineer was canceled, and a small plastic shield was
ultimately developed to block entry of offending light
pulses.