This 2006 Hummer H3 came in with the complaint that the blower had been working sometimes but now the blower motor had stopped working completely. The most common failure point for this system is the blower resistor and it’s harness connector. This repair applies to 2006, 2007, 2008, 2009 & 2010 H3 Hummer. Both are located beneath the glove box area. A simple visual inspection confirmed that this resistor was damaged.
There are some replacement connectors available but I could not get a hold of one, on the day I needed to complete this repair. Also they tend to be rather cheap looking. My plan was to remove the damaged terminals and splice new wire and terminal assemblies into the harness. This would require reusing the red connector body. I have the original terminals in stock.
First I pried the white secondary locking bar from the end connector body.
The plastic around the orange wire (shown below) was melted into the terminal so I had to resort to brute force to remove it.
Since I wanted to reuse the red connector body, I had to take the time to file the cavity out so that the new terminal would fit into the connector body.
By the time I had it filed out enough to accommodate the terminal it would slide through the body some. That is okay since it can only travel so far due to the resistor butting up to it.
If the connector body had been too damaged, I would have removed the excess plastic and slid a piece of heat shrink tubing over the end of the terminal to prevent it shorting out on anything else.
Ultimately, I decided to replace all of the terminals in the connector body.
To insure that everything went together properly I connected the harness to the resistor before I mounted the resistor into the HVAC box.
Looking at the rear of the connector body I could insure that all of the terminals were sitting at the same depth on the connector body.
I had to extend the wires in order to perform this repair.
As a the wires initially hung down below the glove box in a loop.
I had to take my time and form the wires so that they curved back up into the dash and away from any careless feet or other foreign objects.
I was careful to make sure the terminal stayed fully seated in the connector and resistor.