How do you replace the heater resistor pack on a 1996 GMC Safari?

Answer 1

Open the hood. On the passenger side of the engine compartment, you will see the radiator overflow/combination windshield washer bottle. Using a pair of dikes, carefully remove the presstabs holding this container in. It will be necessary to use a pair of pliers to remove the clamp holding the radiator overflow hose from the tank. Also, you will need to unplug the windshield washer pump plug. Take care not to break the pump off of the tank. Remove the pump hoses with gently pulling. Remove the tank. Mounted to the lower portion of the black, plastic evaporator case you will see a square, electronic unit with a plug on it. Remove the plug using a small, flatblade screwdriver to release the latch. Using a 1/4 inch ratchet with a 5.5mm socket, remove the two gold screws holding the resistor board to the case. The new resistor may be slightly different than the old one and may even require a slight modification (cutting of part of the unused portion of the board to fit. You will see what I am talking about, if necessary) Install the new board using the original screws and reinstall the plug. Do not be surprised if the new board fails shortly after installation as GM has been having serious problems with this unit (which is probably why the new board is slightly different than the original). Generally what is happening is that the high blower relay portion of the boards (original and new)are failing. If this occurs, write me back and I will tell you how to install your own external high blower relay. After the ground fails, write me back again and I will tell you how to supply a 'false' ground to correct this problem as well. Whew! Good luck! SDIgroup