GMC Yukon 2000–2006
Common on this vehicle:Gauge or instrument faultWarning lightNoiseAir conditioning or heaterLeakLoss of engine power, no accelerationSmoke or fireCorrosion or rust
Possible causes
The documents say what to doOnly records name itThe size of a node, the width of a link and the numbers are records matching this search, not likelihoods.
FaultCrate・GMC Yukon 2000–2006・Corrosion or rust, Electrical, wiring and power, 2004
Candidate cause (the documents say what to do)
HVAC blower motor resistor module / connector overheating
The terminal interface between the relay resistor module and its power connector may be unable to carry higher current for sustained blower operation.
Moisture and contaminants may enter the fresh air intake plenum and reach the module's circuit or corrode the terminals.
What to do
- Dealers install a new blower motor resistor and resistor module connector.
- Cut the wires back far enough to remove any melted insulation.
Caution: The connector must be replaced even if it was replaced in an earlier repair.
What is needed
- Parts and materials
- New blower motor resistor
- Resistor module connector (replaced even if it was replaced in an earlier repair)
- Labor time
- Not stated
- Special tools
- Not stated
- Scan tool
- Not stated
Only what the technical documents state. "Not stated" does not mean not needed.
In the records
No record states work done for this cause.
Outside the documents and the records
The five pages read are two on 2003 Tahoes, one each on a 2004 and a 2006 Silverado, and one on a 2005 Sierra; none is a record of a Yukon or Yukon XL. All are questions and answers on Q&A sites, and none reports how the repair ended.
- A blower motor taking too much current is named by a 2CarPros responder (2006 Silverado, a black wire that heats up and melts) as one possible cause alongside a bad connection, and by a Car Talk replier (2005 Sierra, no air from the vents) as what in some cases melts the connectors at the motor or at the resistor. In a Car Talk thread on a 2003 Tahoe (blower runs only on setting 5), repliers write that a motor that turns stiffly often burns out the resistor. 2CarProsCar Talk CommunityCar Talk Community
- The asker on 2CarPros with a 2004 Silverado (manual A/C, 199,000 miles (= 320,259 km)) writes that after replacing the melted resistor together with its connector the blower ran only on setting 5 and the resistor and wires became extremely hot; the responder answers that a motor drawing too much current is possible but not very common. 2CarPros
- In a 2CarPros question on a 2006 Silverado (the black wire gets hot and melts), the responder says the black wire is the ground and tells the asker to check the connector for a corroded, damaged or pushed-in pin, whether the wire was earlier replaced with a lighter gauge, and ground G200 near the A-pillar. 2CarPros
- The asker on 2CarPros with a 2003 Tahoe (168,000 miles (= 270,370 km)) writes that the blower would not turn off or change speed and that the battery went dead unless the 40 amp fuse under the hood was pulled, and later that there was no separate relay: relay and resistors were one unit under the dash. 2CarPros
- For the price of the part, a 2011 post in the 2CarPros thread on the 2003 Tahoe gives $45 for a resistor and $66 for a module, and a 2023 reply in the Car Talk thread on the 2005 Sierra gives under $30 for the resistor. 2CarProsCar Talk Community
The sentences above were written by FaultCrate from what shops' public pages and Q&A sites state as fact (none of the pages' wording is shown; a second reader checked each against its pages). A record of another vehicle says which vehicle. A Q&A thread is a question and advice, and may not say how the repair ended. The links below are places to look; the contents of pages not read were not checked.
The pages read, and other places to look (11)
Repair videos
- 03 - 06 Silverado/Sierra Blower Resistor and Connector Replacement (manual HVAC system CJ3)YouTube, Silverado / Sierra 03-06, not read
- 2003 to 2006 Silverado and Sierra Blower Resistor and Harness ReplacementYouTube, Silverado / Sierra 2003-2006, not read
- Blower Motor resistor replacement Silverado Sierra Tahoe Yukon Suburban Esclade 2003-2006YouTube, Silverado, Sierra, Tahoe, Yukon, Suburban, Escalade 2003-2006, not read
- Blower Motor Resistor Meltdown 2005 Chevy Silverado 1500 HD and How To Fix It.YouTube, 2005 Chevy Silverado 1500 HD, not read
Forums and Q&A
- 2004 Chevrolet Silverado Blower Resistor Melted2CarPros, 2004 Chevrolet Silverado (5.3L V8, 4WD), 2015
- 2006 Chevrolet Silverado Blower Resistor Wiring Black Wire Gets Hot and Melts2CarPros, 2006 Chevrolet Silverado (4.3L V6, 2WD), 2023
- 2003 Chevrolet Tahoe 2003 Chevy Tahoe Blower Will Not Turn Off2CarPros, 2003 Chevrolet Tahoe (V8, 4WD), 2009
- 2003 Chevy Tahoe blower control issueCar Talk Community, 2003 Chevy Tahoe, 2011
- My 05 Sierra doesn’t blow ANY airCar Talk Community, 05 GMC Sierra, 2023
- Blower Motor Resistor Connectortahoeyukonforum.com, no vehicle stated, not read
- 2005 recall blower resistor do they just replace part or fix it ? - 1999-2013 Silverado 1500 & Sierra 1500gm-trucks.com, 1999-2013 Silverado 1500 & Sierra 1500, not read
See the evidence (1 technical documents, 1 records)
Passages of the technical documents
The special coverage applies to 2003-2006 GMC Yukon and Yukon XL (and the other listed trucks) with manual HVAC (CJ3) or heavy duty heater (C42).
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)
General Motors (filed with NHTSA) 2012-01-01
The terminal interface between the relay resistor module and its power connector may be unable to carry higher current for sustained blower operation.
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.
General Motors (filed with NHTSA) 2012-01-01
Moisture and contaminants may enter the fresh air intake plenum and reach the module's circuit or corrode the terminals.
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.
General Motors (filed with NHTSA) 2012-01-01
The relay resistor module or wiring connector could overheat and the HVAC blower may not function on certain blower settings or may be inoperative.
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.
General Motors (filed with NHTSA) 2012-01-01
Records
- Blower resistor module corrosion from water entry into HVAC system Owner complaint 2016-08-22
A cause or a result a complaint states is the owner’s view or what a dealer told them, not an established fact.
Put together by FaultCrate from public records and technical documents. The cause and the repair are for the workshop to decide with the vehicle in front of it. Counts are records, not failure rates.

