SB-10240

SB-10038760-3962
Bulletin No.: 10240A
Date: January 2012
Service Bulletin
SPECIAL COVERAGE
SUBJECT: 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
2003-2006 GMC Yukon, Yukon XL
2003-2007 GMC Sierra
Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42)
Customer letters for this Special Coverage were mailed in phases. Letters for the final phase will
begin mailing on January 4, 2012, and so the reimbursement expiration date for this Special
Coverage has been extended to January 31, 2013. Please discard all copies of bulletin 10240,
issued May 2011.
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 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 new blower motor resistor and resistor module connector. The repairs
will be made at no charge to the customer.
Copyright 2012 General Motors. All Rights Reserved.
Page 2
January 2012
Bulletin No.: 10240A
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.
PART INFORMATION
Parts required to complete this special coverage are to be obtained from General Motors
Customer Care and Aftersales (GMCC&A).
Part Number
15862656
89019088
89019089
Description
Connector, SW-Pwr St Adjr
Resistor, Blo Mot (A/C & Htr)
Resistor, Blo Mot (Heater Only)
Quantity/Vehicle
1
1
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
1.
Remove the blower fuses (Htr A/C & HVAC 1 fuses).
2.
Lower the close-out panel enough to gain access to the resistor module connector.
3.
Disconnect the connector from the resistor module.
Note: Connector replacement is required even if the connector was replaced on a previous
service repair.
4.
Remove the tape from the wiring harness to expose the wiring.
Page 3
January 2012
Bulletin No.: 10240A
1709080
5.
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.
6.
Install the new connector. Use the yellow splice sleeves provided with the connector.
7.
Install the new blower motor resistor.
8.
Reinstall the fuses. Test the blower motor to make sure all speeds are functional.
9.
Reinstall the hush panel/close-out panel.
CUSTOMER REIMBURSEMENT - For US
Customer requests for reimbursement of previously paid repairs to correct the condition
described in this bulletin are to be submitted to the dealer by January 31, 2013, unless otherwise
specified by state law. If this is not convenient for the customer, they may mail the completed
form and all required documents to the GM Customer Assistance Center. Repairs must have
occurred within the 10 years of the date the vehicle was originally placed in service, or 150,000
miles, 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 through GM GlobalConnect.
The name and address of the person who paid for the repair.
Paid receipt confirming the amount of the repair expense, a description of the repair, and
the person or entity performing the repair.
IMPORTANT: 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 approved or denied 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.
Page 4
January 2012
Bulletin No.: 10240A
Claims for customer reimbursement on previously paid repairs are to be submitted as required
by GWM.
CUSTOMER REIMBURSEMENT - For Canada and Export
Customer requests for reimbursement of previously paid repairs to correct the condition
described in this bulletin are to be submitted to the dealer prior to or by January 31, 2013.
Repairs must have occurred within the 10 years of the date the vehicle was originally placed in
service, or 240,000 kilometers, whichever occurs first.
When a customer requests reimbursement, they must provide the following:
-
Proof of ownership at time of repair.
Original paid receipt confirming the amount of unreimbursed repair expense(s) (including
Service Contract deductibles), a description of the repair, and the person or entity
performing the repair.
If the work was done by someone other than a GM dealership, the amount of reimbursement will
be limited to the amount that the repair would have cost GM to have it completed by a GM
dealership.
COURTESY TRANSPORTATION – For US
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within
the warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no
charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for
Courtesy Transportation guidelines.
WARRANTY TRANSACTION INFORMATION
Submit a transaction using the table below.
Labor
Code
T5816
T5817
T5818
T5819
Description
Diagnostic Time Only – No Repair Required (condition other than
described in bulletin)
Replace HVAC Module Connector and Resistor
Customer Reimbursement Approved
Customer Reimbursement Denied - For US dealers only
Labor
Time
0.1-0.3
Net
Item
N/A
0.6
0.2
0.1
N/A
*
N/A
* The amount identified in “Net Item” should represent the dollar amount reimbursed to the
customer.
Page 5
January 2012
Bulletin No.: 10240A
CUSTOMER NOTIFICATION
General Motors will notify customers of this special coverage on their vehicles (see copy of
typical customer letter included with this bulletin - actual divisional letter may vary slightly).
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 tools, equipment, 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 dealer for
information on whether your vehicle may benefit from the information.
We Support
Voluntary Technician
Certification
Page 6
January 2012
Bulletin No.: 10240A
Dear General Motors Customer:
As the owner of a 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon,
Yukon XL; or 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicle, your
satisfaction with our product is very important to us.
This letter is intended to make you aware of a condition that may affect your vehicle. The relay
resistor module (which controls blower motor speed) and/or the wiring connector that powers the
module may overheat during sustained blower motor operation, or if moisture and other
contaminants contact the internal circuit of the module. These occurrences may result in an
inoperative blower motor, or result in a blower motor that functions only on certain settings. This
may be accompanied by a burning smell or smoke.
Do not take your vehicle to your GM dealer as a result of this letter unless you believe that
your vehicle has the condition as described above.
What We Have Done: General Motors is providing owners with additional protection for this
condition. If this condition occurs on your 2003-2006 model year Chevrolet Avalanche,
Suburban, Tahoe; GMC Yukon, Yukon XL; or 2003-2007 model year Chevrolet Silverado and
GMC Sierra vehicle, equipped with a manual HVAC or heavy duty heater, within 10 years of the
date your vehicle was originally placed in service or 150,000 miles (240,000 km), whichever
occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for
conditions other than the condition described above is not covered under this special coverage
program.
What You Should Do: If you believe that your vehicle has the condition described above, repairs
and adjustments qualifying under this special coverage must be performed by a General Motors
dealer. You may want to contact your GM dealer to find out how long they will need to have your
vehicle so that you may schedule the appointment at a time that is convenient for you. This will
also allow your dealer to order parts if they are not already in stock. Keep this letter with your
other important glove box literature for future reference.
Reimbursement: If you have paid for repairs for the condition described in this letter, please
complete the enclosed form and present it to your dealer with all required documents by January
31, 2013, unless otherwise specified by State law.
If you have any questions or concerns that your dealer is unable to resolve, please contact the
appropriate Customer Assistance Center at the number listed below.
Division
Number
Chevrolet
GMC
Guam
Puerto Rico – English
Puerto Rico – Español
Virgin Islands
1-800-222-1020
1-800-462-8782
65-6267-1752
1-800-496-9992
1-800-496-9993
1-800-496-9994
Text Telephones
(TTY)
1-800-833-2438
1-888-889-2438
Page 7
January 2012
Bulletin No.: 10240A
We are sorry for any inconvenience you may experience; however we have taken this action in
the interest of your continued satisfaction with our products.
Jim Moloney
General Director,
Customer and Relationship Services
Enclosure
10240

SB-10038760-8811
Bulletin No.: 10240
Date: May 2011
Service Bulletin
SPECIAL COVERAGE
SUBJECT: 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
2003-2006 GMC Yukon, Yukon XL
2003-2007 GMC 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 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 new blower 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.
Copyright 2011 General Motors. All Rights Reserved.
Page 2
SB-10038760-8811
May 2011
Bulletin No.: 10240
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.
PART INFORMATION
Parts required to complete this special coverage are to be obtained from General Motors
Customer Care and Aftersales (GMCC&A).
Part Number
15862656
89019088
89019089
Description
Connector, SW-Pwr St Adjr
Resistor, Blo Mot (A/C & Htr)
Resistor, Blo Mot (Heater Only)
Quantity/Vehicle
1
1
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
1.
Remove the blower fuses (Htr A/C & HVAC 1 fuses).
2.
Lower the close-out panel enough to gain access to the resistor module connector.
3.
Disconnect the connector from the resistor module.
Note: Connector replacement is required even if the connector was replaced on a previous
service repair.
4.
Remove the tape from the wiring harness to expose the wiring.
SB-10038760-8811
May 2011
Page 3
Bulletin No.: 10240
1709080
5.
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.
6.
Install the new connector. Use the yellow splice sleeves provided with the connector.
7.
Install the new blower motor resistor.
8.
Reinstall the fuses. Test the blower motor to make sure all speeds are functional.
9.
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 by 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 through GM GlobalConnect.
The name and address of the person who paid for the repair.
Paid receipt confirming the amount of the repair expense, 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 approved or denied 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.
SB-10038760-8811
May 2011
Page 4
Bulletin No.: 10240
COURTESY TRANSPORTATION – For US
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within
the warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no
charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for
Courtesy Transportation guidelines.
WARRANTY TRANSACTION INFORMATION
Submit a transaction using the table below.
Labor
Code
T5816
T5817
T5818
T5819
Description
Diagnostic Time Only – No Repair Required (condition other than
described in bulletin)
Replace HVAC Module Connector and Resistor
Customer Reimbursement Approved
Customer Reimbursement Denied - For US dealers only
Labor
Time
0.1-0.3
Net
Item
N/A
0.6
0.2
0.1
N/A
*
N/A
* The amount identified in “Net Item” should represent the dollar amount reimbursed to the
customer.
CUSTOMER NOTIFICATION
General Motors will notify customers of this special coverage on their vehicles (see copy of
typical customer letter included with this bulletin - actual divisional letter may vary slightly).
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 tools, equipment, 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 dealer for
information on whether your vehicle may benefit from the information.
We Support
Voluntary Technician
Certification
SB-10038760-8811
May 2011
Page 5
Bulletin No.: 10240
Dear General Motors Customer:
As the owner of a 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon,
Yukon XL; or 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicle, your
satisfaction with our product is very important to us.
This letter is intended to make you aware of a condition that may affect your vehicle. The relay
resistor module (which controls blower motor speed) and/or the wiring connector that powers the
module may overheat during sustained blower motor operation, or if moisture and other
contaminants contact the internal circuit of the module. These occurrences may result in an
inoperative blower motor, or result in a blower motor that functions only on certain settings. This
may be accompanied by a burning smell or smoke.
Do not take your vehicle to your GM dealer as a result of this letter unless you believe that
your vehicle has the condition as described above.
What We Have Done: General Motors is providing owners with additional protection for this
condition. If this condition occurs on your 2003-2006 model year Chevrolet Avalanche,
Suburban, Tahoe; GMC Yukon, Yukon XL; or 2003-2007 model year Chevrolet Silverado and
GMC Sierra vehicle, equipped with a manual HVAC or heavy duty heater, within 10 years of the
date your vehicle was originally placed in service or 150,000 miles (240,000 km), whichever
occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for
conditions other than the condition described above is not covered under this special coverage
program.
What You Should Do: If you believe that your vehicle has the condition described above, repairs
and adjustments qualifying under this special coverage must be performed by a General Motors
dealer. You may want to contact your GM dealer to find out how long they will need to have your
vehicle so that you may schedule the appointment at a time that is convenient for you. This will
also allow your dealer to order parts if they are not already in stock. Keep this letter with your
other important glove box literature for future reference.
Reimbursement: If you have paid for repairs for the condition described in this letter, please
complete the enclosed form and present it to your dealer with all required documents by May 31,
2011, unless otherwise specified by State law.
If you have any questions or concerns that your dealer is unable to resolve, please contact the
appropriate Customer Assistance Center at the number listed below.
Division
Number
Chevrolet
GMC
Guam
Puerto Rico – English
Puerto Rico – Español
1-800-222-1020
1-800-462-8782
65-6267-1752
1-800-496-9992
1-800-496-9993
Text Telephones
(TTY)
1-800-833-2438
1-888-889-2438
SB-10038760-8811
May 2011
Page 6
Virgin Islands
Bulletin No.: 10240
1-800-496-9994
We are sorry for any inconvenience you may experience; however we have taken this action in
the interest of your continued satisfaction with our products.
Jim Moloney
General Director,
Customer and Relationship Services
Enclosure
10240

CSC-10038760-5879
Page 6
January 2012
Bulletin No.: 10240A
Dear General Motors Customer:
As the owner of a 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon,
Yukon XL; or 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicle, your
satisfaction with our product is very important to us.
This letter is intended to make you aware of a condition that may affect your vehicle. The relay
resistor module (which controls blower motor speed) and/or the wiring connector that powers the
module may overheat during sustained blower motor operation, or if moisture and other
contaminants contact the internal circuit of the module. These occurrences may result in an
inoperative blower motor, or result in a blower motor that functions only on certain settings. This
may be accompanied by a burning smell or smoke.
Do not take your vehicle to your GM dealer as a result of this letter unless you believe that
your vehicle has the condition as described above.
What We Have Done: General Motors is providing owners with additional protection for this
condition. If this condition occurs on your 2003-2006 model year Chevrolet Avalanche,
Suburban, Tahoe; GMC Yukon, Yukon XL; or 2003-2007 model year Chevrolet Silverado and
GMC Sierra vehicle, equipped with a manual HVAC or heavy duty heater, within 10 years of the
date your vehicle was originally placed in service or 150,000 miles (240,000 km), whichever
occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for
conditions other than the condition described above is not covered under this special coverage
program.
What You Should Do: If you believe that your vehicle has the condition described above, repairs
and adjustments qualifying under this special coverage must be performed by a General Motors
dealer. You may want to contact your GM dealer to find out how long they will need to have your
vehicle so that you may schedule the appointment at a time that is convenient for you. This will
also allow your dealer to order parts if they are not already in stock. Keep this letter with your
other important glove box literature for future reference.
Reimbursement: If you have paid for repairs for the condition described in this letter, please
complete the enclosed form and present it to your dealer with all required documents by January
31, 2013, unless otherwise specified by State law.
If you have any questions or concerns that your dealer is unable to resolve, please contact the
appropriate Customer Assistance Center at the number listed below.
Division
Number
Chevrolet
GMC
Guam
Puerto Rico – English
Puerto Rico – Español
Virgin Islands
1-800-222-1020
1-800-462-8782
65-6267-1752
1-800-496-9992
1-800-496-9993
1-800-496-9994
Text Telephones
(TTY)
1-800-833-2438
1-888-889-2438
Page 7
January 2012
Bulletin No.: 10240A
We are sorry for any inconvenience you may experience; however we have taken this action in
the interest of your continued satisfaction with our products.
Jim Moloney
General Director,
Customer and Relationship Services
Enclosure
10240