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Hi. A couple weeks ago the resistor died for the heater fan on my wife's 2004 Silverado. I bought one at the local parts store for $65.00 because I needed it in a hurry. It made it two weeks and now it is cooked again. The black ground wire in the plug that plugs into the resistor is also burned. I suppose if I buy another resistor it will work for a while before burning out again, but I think there's something else wrong. The 30a fuse is fine. I took the old red and black wire from the fan and plugged them into the harness that plugs into the resistor to get some heat for now. I'd welcome any thoughts. Thanks.
 

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Did it all go at once? Mine lost the lowest two speeds but the other three are still okay. I'm guessing its the rheastat but haven't torn it apart yet
 

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Hi. A couple weeks ago the resistor died for the heater fan on my wife's 2004 Silverado. I bought one at the local parts store for $65.00 because I needed it in a hurry. It made it two weeks and now it is cooked again. The black ground wire in the plug that plugs into the resistor is also burned. I suppose if I buy another resistor it will work for a while before burning out again, but I think there's something else wrong. The 30a fuse is fine. I took the old red and black wire from the fan and plugged them into the harness that plugs into the resistor to get some heat for now. I'd welcome any thoughts. Thanks.
I Would Just Mention that there Was a Special Coverage Adjustment from GM regarding the Problem with the Blower Motor Resistor.....

Below the GM Service Bulletin that goes into Detail about this Problem,

G.M. SERVICE BULLETIN

Special Coverage Adjustment
Bulletin No.: 11046

Date: April 07, 2011


Subject: 11046.......SPECIAL COVERAGE ADJUSTMENT........Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the IGNITION OFF.

Models:
2003-2006 Chevrolet Avalanche, Suburban, Tahoe
2003"-2007" Chevrolet Silverado
2003-2006 GMC Yukon, Yukon XL
2003-2007 GMC Sierra
Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42)

Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter.

The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin.

In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin.

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. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms:

- 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

IN VERY RARE events, if the above Symptoms are Ignored......A FIRE Could Occur
.

SPECIAL COVERAGE ADJUSTMENT.......This Special Coverage Covers the Condition described above for a period of .....10 YEARS or 150,000 MILES(240,000km).....whichever occurs first, from the Date the Vehicle was Originally Placed into Service.......Regardless of Ownership.

Dealer are to install a New Blower Motor Resistor & Blower Module Connector......and the Repair will be made at No Charge to the Customer.

Important.......For vehicles covered by Vehicle Service Contracts, All eligible Claims with repair orders on or after April 8 2001 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 April 8 2011 must be Sumitted 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 HVAV (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.
__________________

.......If Your Vehicle is beyond the Special Coverage Adjustment Mentioned above.....and you do the Repairs, next to Replacing the Blower Motor Resistor, the "Blower Motor Resistor Wring Connector" A
lso Needs to be Replaced, as 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....this is A/C Delco Part # PT2195.
 

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if your over the mileage you should get another resistor/relay module with a new connector.

I got a new assy from auto zone several years back. came with a warranty autozone. GM module is made to fail !

the module I got was very much designed to be completely water proof . GM no !
 

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Discussion Starter #6
Thank you all for the information. I e-mailed my local GM dealer. If nothing else, I can change the connector and resistor. This is a great site, and thanks again for your help.
 

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For what it's worth I bought the whole harness, which consists of 3 connectors and is totally plug and play for $39.00 from the dealer, a lot easier than laying upside down trying to solder a new connector on. Gm came out with a revised part, just go to the dealer and ask them. Mines been fine for over a year now.
 

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For what it's worth I bought the whole harness, which consists of 3 connectors and is totally plug and play for $39.00 from the dealer, a lot easier than laying upside down trying to solder a new connector on. Gm came out with a revised part, just go to the dealer and ask them. Mines been fine for over a year now.
You have part numer or anything on that for $40 I wanna jump on it before I lose all my heat or worse my truck
 

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I replaced my reistat about a week ago now everything is good, didn'tuse the harness gm said I needed everything looks good with the wiring....but I highly suggest that everyone atleast check theirs out. We did three other vehicles at work, and all three had melted wires and could have easily caused fires! One was a co-worker and he just swapped out the resistor and I only lasted three days, went back in and found the torched harness.
 

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i got a blower resistor back in 08 or 09 the first thing that happened to the truck after i bought it was the blower motor stopped working. New resistor from dealer cost like 120.00. I think it had been replaced once already because when I looked at the wiring and compared it to my new one the pigtail had been cut, shortened, and looked to have been installed by an 8-year old obviously there was charring around the connector but, after i got mine, all i had to do was wire it to the connector, and it was then plug-n-play. I only replaced the resistor, check it about twice a year and it has been fine ever since, I did apply some di-electric grease that I think was either included w/ the part, or came already pre-lubed and i think that helped tremendously.

edit: i wanted to add that GM never notified me of this issue on my 04 by mail or otherwise, I certainly would've liked to have taken it in and had them install the improved version free of charge, since the resistor pig tail i replaced was exactly the same as the one that came out (sans hacking of the harness) i believe it to still be error prone.
 

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Just my 2 cents on this topicI also replaced my resister,ofcourse it was the more expensive one due to the fact my climate controls are digital.But any way GM did not notify me either and I have owned this truck since '09,its an 04 so well within the ten years.and it still isnt close to 240,000 kms.Think if I gave GM a quick call they will cut me a check,hahahahaha
 

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same thing with mine,, started out just quit working,,, found plug at blower was in bad shape,,fixed that and it worked a week this week all i have is off and high. so i guess a resistor is in my future,,, question i have is why such a big difference in prices ? some vary from 34.00 to 91.00 dollars.



terry m
 

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same thing with mine,, started out just quit working,,, found plug at blower was in bad shape,,fixed that and it worked a week this week all i have is off and high. so i guess a resistor is in my future,,, question i have is why such a big difference in prices ? some vary from 34.00 to 91.00 dollars.
terry m
on many trucks the blower resistor/connector gets burned up melts down . when this happens both need replacing .
I would also use a dielectric grease because water can collect at times there.
 

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Something that is often missed is the ground for that circuit at the passenger side fender. It is inside a ground tree and really needs to be isolated since the heater fan draws so many amps. It really needs a better ground. A poor ground on that circuit will cause excessive amperage draw and overheated wires. GM does not seem to get it. The parts listed will fix it for a time but better securing of that ground will be a permanent fix.
 

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water gets to the blower connector that is were the plastic connector melts down. also on my 2000 the blower resisters were a total defective design should have been a recall .. resistors were a circuit board really cheap crap. the replacement I installed NOT GM has a lifetime warranty and I do drop blower motor and clean it/insp for debris also the air filters in the box there and no blower resistor problems.

if the ground wire to blower motor is bad/corroded loose then the wires a t the blower will not melt but the wire at the ground may get hot and the blower will not blow properly .
 

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Same issue on my friend's 2004.
It lost them all at once. The resistor was only a year old. All speeds went at once. The connectors look good.

My question is if I can run a hot and a ground direct to the blower to make sure it's not the problem without frying the fan. It could end up being a temporary fix until it warms up next week, because we are already getting snow and a defroster would be handy.
 
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