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Old 01-12-2011, 11:16 AM   #1
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Default Rusted out under battery

My battery died last night, got it jumped and drove home then went and got a new one this morning. In the process of taking the old one out I discovered that where the hold down is is pretty much rusted through - I can see to the ground nearby and trying to undo the bolt just makes the entire thing twist. I don't think I can get it out without taking a big chunk of floor with it. Searching the forum I found the following post which tells about a repair kit, but the best price I found for the kit is about $241, plus I don't know if it'* something I could do myself, so labor would be a killer. I really don't want to spend that much... Has anyone else had this problem? Any other solutions besides the repair kit? I need to do something fairly quickly, my dead battery is still stuck in there and getting to work is going to be a problem. Took off today and might tomorrow also, but I need my car back! Thanks in advance for any help!!!
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I think this is somewhat related to the problem (at least in the area of the battery). I've seen it in several Bonnevilles and seems to be a lot more common than I first thought.

Here'* the GM Technical Bulletin.
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Floor Pan Corrosion Perforation in Battery Compartment (Install Repair Kit) #05-08-61-002 - (Jan 11, 2005)
Floor Pan Corrosion Perforation in Battery Compartment (Install Repair Kit)
2000-2005 Buick LeSabre

2000-2005 Cadillac DeVille

2000-2003 Oldsmobile Aurora

2000-2005 Pontiac Bonneville

Condition
Some customers may comment on corrosion (rust) in the floor pan in the area where the battery is located.

Cause
This condition may be caused by a weeping of acid from the battery or from a battery vent tube that has become dislodged.

Correction
Repair the damaged area using the parts and information contained in the floor pan repair panel kit.. Also, clean any area of the floor pan where acid may have been present with a solution of baking soda and water. Rinse and dry the area thoroughly.

Parts Information
The floor pan repair panel kit contains a replacement section of the floor pan, a battery hold down and instructions. The adhesive needs to be ordered at the time of the repair.

Part Number
Description

88948594
Panel Kit-Floor Pan Repair

12378567 (U.*.)

88901675 (Canada)
GM Metal Bonding Adhesive


Parts are currently available from GMSPO.

Warranty Information
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

S5230
Replace Floor Pan
2.6 hrs

Add:
Refinish/Clearcoat
0.7 hr

Add:
Material Codes
GM

Add:
Paint Mix Time
0.3 hr




GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the information.
WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION


Copyright General Motors Corporation. All Rights Reserved.


--------------------------------------------------------------------------------
Document ID# 1581654
2004 Pontiac Bonneville
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Old 01-12-2011, 12:08 PM   #2
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I think its due more to the batteries they use not the tray its self..obviously or they wouldnt have acid leaked on em
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Old 01-12-2011, 12:55 PM   #3
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Default Update!

I took a little water and baking soda to see if I'd get a reaction to tell if it was from acid or just rust and there was no reaction. I lifted my carpet up a little to check for rust under there and sure enough, it is :( I have to get it up more to tell how bad it is. I've had problems with my sunroof leaking but didn't think it was that bad in the back seat, the carpet only got a little wet a couple times that I remember, but I guess that'* enough :/ I'm am getting so fed up with this car. I love it but I don't want to keep pouring money into it if it'* going to keep having so many problems...
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Old 01-14-2011, 10:23 AM   #4
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Quote:
Originally Posted by 2000Supercharged View Post
I I'm am getting so fed up with this car. I love it but I don't want to keep pouring money into it if it'* going to keep having so many problems...

That has been my experience with both our Bonny, Bravada and now S10. What I discovered is that after you fix the many problems and learn how to get good parts on the cheap, they are excellent vehicles that are easy to service. The Bonny is worn out, yet it is still the best sedan I have ever owned and still love it. The 2000 series Bonny had to be GM best sedan they ever built, and nobody knew it, even GM. Our Bonny is beat to crap and ten years old, yet the seats still look like new. Just one example of how well built the Bonnys were. GM screwed up on many little things from window regulators to intake manifold gaskets, but if you are proactive and get it right the Bonny is a dream car.

I will get flamed but I compare the Bonny SSEi to a BMW 5 series. The CTX is the normal comparison, but the CTX has so many deep maintenance issues I think the Bonny is the real deal.

No other USA labeled car other than the Bonny can compare to the BMW 5 series, not even close.
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Old 01-14-2011, 10:35 AM   #5
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If the back seat area is getting wet, you may want to check the wheel wells. The passenger side seems to rust threw and driving in water throws it in to the car. I've seen a few cars where the drive complains of wet floor, wet seat, and wet seat belt when driven in the rain.
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