Blower Resistor 2003-2007 (classic) with MANUAL HVAC Special Policy Repair

Discussion in 'Chevy Silverado Forum (GMC Sierra)' started by junkologist, Dec 18, 2011.

  1. junkologist

    junkologist New Member

    I found this "Special Policy" on another website, today, and will be taking a copy to my GM Dealership's Service Desk. In Oct. 2011, the service dept offered to charge me $92./hr to discover why Heater Blower was not working properly. I declined.
    Regarding the EVAP "leak" or blocked Vapor Canister Vent - This lit up the Check Engine Soon dash light. The dealer's service dept rep claims, he had the code reset but, he is mistaken. It is still lit and the dealer wants $377. + tax to replace and reroute the vapor canister.
    ...................
    This is the 6th or 7th GM truck I've owned and so far, it seems it's the most expensive headache to keep in decent running condition.
    ................
    Blower Resistor 2003-2007(classic) with MANUAL HVAC (CJ3) [HR][/HR]I don't know if this has been posted yet but, i have notice a few threads about blower resistors lately and i want to make people aware. There is a "special policy" (not a recall) for the MANUAL HVAC (RPO CJ3)

    Please read this before before buying a new resistor/harness

    #10240: Special Coverage Adjustment-Heating, Ventilation, and Air Conditioning Blower Not Fully Functional or Inoperative - (May 9, 2011)


    Subject: 10240 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional or Inoperative


    Models: 2003-2006 Chevrolet Avalanche, Suburban Tahoe

    2003-2007 Chevrolet Silverado

    2003-2006GMC Yukon, Yukon XL

    2003-2007GMC Sierra

    Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42)





    --------------------------------------------------------------------------------
    Condition
    On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. If any of these were to occur, the relay resistor module or wiring connector could overheat and the HVAC blower may not function on certain blower settings or may be inoperative. This may be accompanied by a burning smell or smoke.

    Special Policy Coverage Adjustment
    This special coverage covers the condition described above for a period of 10 years or 150,000 miles (240,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership.

    Dealers are to install a newblower motor resistor and resistor module connector. The repairs will be made at no charge to the customer.


    For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after May 10, 2011, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to May 10, 2011, must be submitted to the Service Contract provider.

    Vehicles Involved
    Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42).

    Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system.

    Parts Information
    Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A).

    Part Number
    Description
    Qty/ Vehicle

    15862656
    Connector, SW-Pwr St Adjr
    1

    89019088
    Resistor, Blo Mot (A/C & Htr)
    1

    89019089
    Resistor, Blo Mot (Heater Only)
    1

    Service Procedure
    Note: The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present.

    • The HVAC blower may not function on certain or all blower speed settings

    • A burning plastic smell or smoke may be present in the vehicle

    • The HVAC blower may run continually with the ignition in the OFF position

    Determine if one or more of the above symptoms is present. If required, refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms are present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin.

    Resistor Module Connector and Blower Motor Resistor Replacement
    •Remove the blower fuses (Htr A/C & HVAC 1 fuses).
    •Lower the close-out panel enough to gain access to the resistor module connector.
    •Disconnect the connector from the resistor module.
    Note: Connector replacement is required even if the connector was replaced on a previous service repair.

    •Remove the tape from thewiring harness to expose the wiring.
    •Cut the wires back far enough from the connector to eliminate any melted insulation on the wire.
    Note: Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection.

    •Install the new connector. Use the yellow splice sleeves provided with the connector.
    •Install the newblower motor resistor.
    •Reinstall the fuses. Test theblower motor to make sure all speeds are functional.
    •Reinstall the hush panel/close-out panel.
    Customer Reimbursement
    Customer requests for reimbursement of previously paid repairs for the condition described in this bulletin are to be submitted to the dealer May 31, 2012, unless otherwise specified by State law. Repairs must have occurred within 10 years of the date the vehicle was originally placed in service, or 150,000 miles (240,000 km), whichever occurs first.

    All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer.

    When a customer requests reimbursement, they must provide the following:

    • A completed Customer Reimbursement Request Form. This form is mailed to the customer or can be obtained from the dealer.

    • The name and address of the person who paid for the repair.

    • VIN, original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair.

    For US dealers:
    If a reimbursement request is denied, dealers MUST provide the customer with an explanation, in writing, as to why the request was denied. GM expects all reimbursement requests to be properly resolved within 30 days of receipt. If the denial was due to missing documents, the customer can resubmit when the missing documents are obtained, as long as it is still within the allowed reimbursement period.

    (to be continued in my next post or see where I found this letter, http://www.gmfullsize.com/forum/showthread.php?t=232335 )
     
  2. SurrealOne

    SurrealOne Former Member ROTM Winner 1000 Posts

    Good info. My read on that is it only applies to manual systems not to those with temperature controls, yes?
     
  3. junkologist

    junkologist New Member

    All the details regarding this 2003 - 2007 GM Blower Resistor issue can be found in a copy of a letter from GM ... click on the link at the bottom of my thread, Blower Resistor 2003-2007 (classic) with MANUAL HVAC Special Policy Repair
     
  4. junkologist

    junkologist New Member

    Yes, only manual = has two temperature adjusting sliders in middle of fan speed knob [on left] and air flow direction selector knob [on right].

    ---------- Post added at 10:27 AM ---------- Previous post was at 10:22 AM ----------

    When I brought a copy of the Special Policy Adjustment letter with me, to dealer service desk, I was able to get heater blower Resistor and fan speed Plug replaced Free of Charge !!
    "Merry Christmas"

    ---------- Post added at 10:31 AM ---------- Previous post was at 10:27 AM ----------

    Sur,
    Read the copy of the #10240 letter I posted, above. Apparantly it covers Manual or "Heavy - Duty" heaters.
    ....................................
    #10240: Special Coverage Adjustment-Heating, Ventilation, and Air Conditioning Blower Not Fully Functional or Inoperative - (May 9, 2011)


    Subject: 10240 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional or Inoperative


    Models: 2003-2006 Chevrolet Avalanche, Suburban Tahoe

    2003-2007 Chevrolet Silverado

    2003-2006GMC Yukon, Yukon XL

    2003-2007GMC Sierra

    Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42)
     
  5. jstutz101

    jstutz101 New Member

    This happend to me shortly after I bought my 07 Silverado used. I cranked up the heat on my way to work, heard a POP and smoke started rolling out from under the glove box. It was an easy fix once I realized what it was. Thankfully access to the blower resistor is good.
     
  6. grinner

    grinner New Member

    I bought and replaced the Blower Motor Resister a few years ago. I got the paperwork in the mail to get a refund on the parts and labor. I went down to the dealer where I purchased the part and the Service Manager filled out the paperwork and got my $151.00 for the part back in about 3 days. I was a happy customer.
     
  7. mljjones67

    mljjones67 New Member

    Thanks this good to know...
     

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