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I don't car how many miles it has on it that is a manufacturer's defect. Someone at GM would get a piece of my mind. (as small as it is). That is a simple case of bad welding. A good weld will melt the base metal, the filler metal and the donor piece metal and create a molted mixture. The left weld didn't get hot enough to penetrat the base metal. The right weld only about half of it was a good weld. You can tell a good weld when it breaks, it breaks just outside the weld in the base material. The weld is stronger then the base material after welding.
Man, after reading all of this I don't know if I want to go for a drive in my car or not. Mine was built several months before yours, but I now wonder if anything is wrong. I take mine in on Thursday for a rubbing noise from the rear end (don't know if it is from the differential or some other spot back there). These types of things should not be happening on a $45K car.
I really hope all goes well for you and that GM fixes the car right. Please keep us posted.
Hey Neill, That could have been a disaster if you had been any 'serious' performance driving. As far as a fix, it really doesn't look that bad.......it looks pretty straight forward. Disconnect the upper control arm to get it back in position (use clamps to hold in place if able). Then tack weld it using a MIG welder (with .035 wire). Reconnect the only the control arm ( by itself) to align the bracket then and keep it from moving around while you lay your bead. Your can then weld it on the inside to give it a stronger weld. Shouldn't be that hard.....its just a b!tch you had to do it tin the first place!
Ghost, Unfortunately, the frame rail split open from flexing as the welds failed one by one in use. The rail is too badly compromised to weld the cracks shut and the bracket back on. Neill is stuck with needing a frame sectioning. Sucks, but that's the only remedy for the car.
That sucks. I took my car in to get the clutch replaced and told the mechanic I heard a little noise in the front right side of the car. I came in later that day to say hi and he showed me where one of the upper shock mount bolts was gone and the others were loose. I had run over an already hit deer about 3 months prior, I'm thinking that was the cause. It was a pretty hard hit for a lowered C-5. You might want to check them out too. Good Luck. Justin