Bus Bar Lead Terminal Repair

2004 Oldsmobile Bravada RWDSECTION Bus Bar Lead Terminal Repair
WARNING: This page is about a different car, the 2003 Oldsmobile Bravada, 2003 GMC Envoy XL, 2003 GMC Envoy, and 2003 Chevrolet TrailBlazer. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: The rear defogger bus bar lead wire, the antenna, or the defogger terminal may be reattached by resoldering using a solder containing 3 percent silver and a rosin flux paste.
  1. Clean the repair area by buffing with fine steel wool. This removes the oxide coating formed during the window manufacture.
  2. Install the paste-type rosin flux in small quantities to the rear defogger bus bar lead wire antenna or the defogger terminal repair area using a brush.
  3. Coat the solder iron tip with the solder.
    • Use only enough heat in order to melt the solder.
    • Use only enough solder in order to ensure a complete repair.
  4. Install the solder to the feed bus bar or the ground bus bar.
    Fig 1: Installing Solder To Feed Bus Bar Or Ground Bus Bar
    G01641275Courtesy of GENERAL MOTORS CORP.
  5. Draw the soldering iron tip across the fluxed area, thinly coating the bus bar with solder.
  6. Install a small amount of flux to the underside of the rear defogger bus bar lead wire antenna or the defogger terminal.
  7. Align the spots with flux to the underside of the rear defogger bus bar lead wire, antenna, or defogger terminal.
  8. Coat the tip of the soldering iron with solder.
  9. Install the solder to the underside of the rear defogger bus bar lead wire antenna to the defogger terminal.
  10. Draw the iron across the fluxed spot, thinly coating the spot of solder.
  11. Solder the spot on the braid against the spot on the feed bus bar or the ground bus bar.
    • Use pliers in order to hold the rear defogger bus bar lead wire antenna or the defogger terminal.
    • Apply the heat to the top of the rear defogger bus bar lead wire antenna or the defogger terminal. This causes the solder spot to melt and fuse together.
    • Do not remove the holding force until the solder has solidified.
    • Wipe off the excess flux with solvent.
  12. Connect the electrical connector.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • You smell fuel, burning insulation, or see smoke.
  • Brakes feel soft, pull hard to one side, or make grinding noises.
  • The engine overheats, stalls repeatedly, or misfires under load.
  • You are missing required tools, torque specs, or safe lifting equipment.
  • You are not confident in the next step or safety outcome.