GMC Yukon XL 2000–2006
Common on this vehicle:Gauge or instrument faultWarning lightCorrosion or rustNoiseLeakReduced brakingStalls or shuts offLoss of engine power, no acceleration
There are 2,120 records on the 2000–2006 GMC Yukon XL (Owner complaint: 983, Recall: 38, Manufacturer communication: 1,099). The documents describe 143 known issues; those with the most records under them are Gauges stick or flutter (138), Brake pipe corrosion (135), ABS activation at low speed (52).
Possible causes
144 causes not drawn
- Voltmeter fluctuates between 12 and 14 volts (Regulated Voltage Control, normal)3
- Hydro-boost brake assist and power steering share one hydraulic supply (four campaigns)19
- Brake pedal moves or self applies at full steering lock (Hydro-Boost)2
- Brake pedal pushrod retainer missing - recall 05V-1031
- Cosmetic brake rotor corrosion: burnish, do not resurface1
- ABS light with C0265/C0201/U1041 or no communication with brake module (EBCM ground G110)1
- Front right-hand brake pipe contact with body cross sill - recall 00V-3451
- DIC “Reduced Brake Power” message and reduced vacuum boost1
- Service Brake Booster message on a Hydroboost vehicle with DTC C0136 (instrument cluster not SPS programmed)1
- Stability System Disabled / Service Stability message with DTC C0455 (bent terminals at the steering wheel position sensor)1
- Violent steering wheel shake or vibration at road speed (brake booster)1
- Brake Rotor: corroded, worn11
- Aftermarket part (not the vehicle as built): Federal-Mogul National / Carquest replacement wheel hub assembly retention nut - recall 07E-1062WD only1
- Grease seen at front hub bearing seals (normal purge, do not replace)1
- Creak or squeak noise from the rear lower control arm bushings (do not replace the propshaft)1
- Upper control arm bracket alignment (dowel) pin missing at front end alignment1
- Vehicle body tilt or lean left / right (torsion bar front suspension)1
- Tire: broken, failed31
- Tire Tread and Belt: broken, failed5
- DTC P0446 set with the SES lamp on (replace the EVAP vent solenoid, not the canister)3
- Fuel pressure regulator buzz / hum after replacement (check fuel pump feed voltage drop and connector crimps)4.8L, 5.3L, 6.0L only2
- Engine fuel rail crossover tube retainer screws may break (5.3L RPO L59) - recall 04V-3765.3L only2
- Engine fuel rail pulse damper retainer clip may fracture (8.1L V8) - recall 06V-289 / Transport Canada 20061958.1L only2
- Slow or short fuel fill, inaccurate fuel gauge (2500: fuel tank vent)2500 only1
- Fuel gauge reads low or drops to empty in Park / Neutral (normal characteristic)1
- Fuel Pump: failed, leaking19
- Fuel Line: broken, leaking2
- Fuel Tank: leaking2
- Driver's seatback moves during braking (recliner replacement)3
- Center console lid hard to open or close (lubricate the latch)2
- RPO DL3 power folding mirror loose, moves or shakes after being folded by hand (cycle it electrically)2
- Door manual lock lever disengages from the door trim panel (lock lever replacement)2
- Bench seat (RPO AE7) center console armrest hinges broken (replace the lid, not the console assembly)1
- Rattle from the center of the dash (cowl insulator clip)1
- Door sags or is hard to open or close (worn or corroded hinge pins and bushings)1
- Front seat adjuster switch knob loose or missing (replace only the switch cover)1
- Headliner or roof rattle (roof drain channel)1
- Broken latch of the rear cupholder in the center console (replace the latch only)1
- Rear door upper hinge welds out of specification (FMVSS 214) - recall 03V-0371
- Side access door noise (door check link replacement)1
- Factory trailer hitch receiver bent, broken or weld failure1
- Liftgate Glass Hinge: broken, loose or misadjusted17
- Rear Window Glass: broken, loose or misadjusted7
- Spare Tire Carrier Winch Cable: broken, corroded4
- Frame: corroded3
- Tire scrub noise on low speed turns (steering rod / centerlink installed backwards)1
- Pitman Arm: design or manufacturing1
- Steering Gear Box: leaking2
- Pitman Arm Shaft Seal: leaking1
- Power Steering Line: corroded1
- Remote keyless entry and front passenger door window, lock, mirror inoperative (reprogram the Passenger Door Module)13
- Reduced Engine Power from throttle body connector crimp, broken wire or grounds7
- Ground Ring Terminal: loose or misadjusted3
- CD slow to play, CHECK CD error, CD stuck or clock resets to 12:00 (reprogram the radio, do not replace it)2
- Rear seat audio and/or rear HVAC controls inoperative (replace the RSA, not the console)2
- Trailer brakes applied whenever headlamps or park lamps are on (brake controller jumper harness)2
- Starter keeps cranking after the key is released (PCM-controlled automatic crank, normal)5.3L only2
- Generator whine in the audio system (new ground for radio and amplifier)1
- Intermittent battery drain from a sticking A/C compressor relay1
- Intermittent battery lamp with history DTC B1489 after BGCM replacement (module not SPS programmed)1
- Intermittent MIL, service lamps/messages or DTCs from connector fretting corrosion1
- Positive battery cable contact with steering shaft universal joint (Denali) - Transport Canada 20010921
- Memory seat recalls to a more-forward position than set (memory seat module software)1
- No audio out of the speakers at times (radio reprogram or amplifier replacement)1
- Poor radio reception from a loose radio antenna mast1
- Radio shows a disc error when a media disc is inserted (unsupported disc format or damaged disc)1
- No audio and no radio display, or radio clock resets (2004; radio set-up with the Tech 2)1
- Red radio theft LED does not flash (manufacturer's counter not reset at assembly)1
- Rear wiper jumps when the fog lamps are turned on (auxiliary ground to rear washer pump)1
- Seat heater or memory power seat inoperative (memory seat control module)1
- Turn signal flashes fast (export flasher relay installed)1
- Hum or fan noise from the navigation radio (internal cooling fan, normal)1
- Radio volume lower at the same setting after reprogramming or replacement (new audio calibration, normal)1
- Replacement headlamp switch has no LED indicators and sets DTC B0951 (2003, normal)1
- Keyless Entry Transmitter: failed5
- Battery: leaking, design or manufacturing3
- Wiring: overheated, broken3
- Intake manifold gasket leak (cold idle misfire, lean codes)11
- Oil leak after cold start from frozen PCV system (rear main seal)6
- Single-cylinder misfire (P0300-P0308) and/or chirp, squeak or tick at camshaft speed: worn cam lobe / lifter, valve or valve spring5
- Engine Block5
- Increased accelerator pedal effort / throttle body sticks (clean and adjust, do not replace)4.8L, 5.3L, 6.0L only4
- Crankshaft position sensor may work intermittently or fail (8.1L V8) - recall 07V-5218.1L only4
- Cylinder4
- Lean hesitation, sag or stumble at -6 to +20°C coolant temperature (PCM reprogram)4.8L, 5.3L, 6.0L only2
- Higher than expected oil consumption at 8600 GVW and above (accepted rate and consumption test)2
- Rear bank knock sensor corrosion from water intrusion (P0332)4.8L, 5.3L, 6.0L only2
- Accessory drive belt whine (power steering pump pulley repositioned)1500 only1
- Castech cylinder head porosity crack (gradual coolant loss)4.8L, 5.3L only1
- Higher than expected engine oil consumption (PCV valve replacement)4.8L, 5.3L, 6.0L only1
- P0300 after engine repairs: injector connectors crossed (cylinders 5-7 / 6-8)1
- Slight roughness at idle with no DTCs (possible characteristic)1
- 4L80-E / 4L85-E planetary gear whine in first and second gear3
- 4L60-E burnt 3-4 clutch pack1
- 4L60-E slip or no forward engagement right after input housing replacement (service part 17803687)1
- Whine noise from the rear axle (tuned torsional damper propeller shaft)1
- Service 4WD indicator and DTC B2725 (transfer case shift control switch)4WD / AWD only1
- 4WD/AWD lamps and system inoperative: "sleepy" New Venture Gear transfer case control module (reprogram the TCCM)4WD / AWD only1
- Transfer case service light, New Venture Gear transfer case (replace the encoder motor sensor and reprogram the TCCM)1
- Electronic transfer case stops shifting with no DTC (shift abuse lock out mode, normal)1
- Transfer case speed sensor connector locks bend on disconnect (improved connector)1
- 4L60-E / 4L65-E clunk on 2-3 upshift or 3-2 downshift (normal condition)1
- Transmission: failed7
- Differential: clogged or contaminated, failed3
- Front Differential: failed2
- Engine compartment noise with A/C on and A/C inoperative (auxiliary rear A/C: suction hose and compressor)3
- No passenger compartment air filter (not available from the 2003 model year; normal)2
- Climate Control Module: electrical fault, software2
- A/C blows warm at extended idle (6.0L: auxiliary electric cooling fan)6.0L only1
- HVAC actuator clicking / ticking noises (recalibrate the HVAC control module, do not replace actuators)1
- Loss of HVAC mode or temperature control (wiring harness rerouted)1
- Passenger side colder or warmer than the driver's side (HVAC case to cowl seal)1
- Insufficient heat from the rear heater in extreme cold (tee coupling replacement)1
- Rear HVAC ticking noise, no rear temperature or mode control, DTC B0434 / B3764 (revised auxiliary HVAC control module)1
- Air Conditioning Compressor: failed2
- Air Conditioning Cycling Switch: failed1
- Air Conditioning Line: corroded1
- OnStar System: failed, software5
- Some OnStar features no longer work (2G cellular sunset; the module is not broken)2
- OnStar cannot configure the vehicle (118 error) after the 15-08-44-001 upgrade1
- No response when the OnStar button is pressed (DTC B2476): button assembly test values1
- Red OnStar LED and DTC B2455 after Canada upgrade bulletin 15-08-44-001 (audio and microphone drain wires shorted)1
- Digital Radio Receiver: failed1
- OnStar Module: electrical fault1
- CD Player: overheated, software2
- OnStar Hardware: software1
- Radio: failed1
- P0420 / P0430 on a new or just-replaced catalytic converter (break-in not completed)4
- Exhaust pop or ping noise (replace the heat shield, not the exhaust system)1
- Purge Solenoid: failed1
- Air bag sensing diagnostic module (SDM) anomaly - recall 02V-1782
- Air bag lamp on with DTC B0092 (passenger presence system sensor harness)1
- AIR BAG indicator on with side impact module DTCs (connector CPA replacement)1
- 2nd/3rd row outboard seat belt retractor internal crack - recall 01V-1591
- Second row seat belt retractor does not lock automatically for a child restraint1
- SIR lamp on and inside mirror temperature/compass display inoperative (open air bag fuse, circuit 1139 shorted to ground)1
- Airbag Sensor: failed2
- Side Impact Module: electrical fault, failed2
- Tire and loading information label lists inaccurate vehicle capacity weight (FMVSS 110) - recall 05V-5521
- Bearing: broken, failed2
- Bolt: broken, loose or misadjusted2
- Seal: failed1
- Radiator: failed2
- Water Pump: failed1
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 XL 2000–2006
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
- Blower Resistor: replaced 1(result not stated: 1)
- Power Connector: replaced 1(result not stated: 1)
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, 5 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
- HVAC Blower Motor Resistor Module Overheating Recall 2011-02-21
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.
Pages by symptom, trouble code and warning display (79)
One page each, only where the technical documents say how to deal with a cause.

