2005 Yukon 5.3 Cooling Fan won't turn off - SOLVED

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Dad28

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I have solved my problem, but wanted to post for others to see. Sometimes I find posts where people offer solutions, but the OP never lets you know what fixed it.

2005 Yukon SLT 5.3 - 295,000 miles - automatic dual climate control

Original Symptoms
1. Overheating
2. Electric cooling fans would not turn on.
3. A/C doesn't blow cold
4. Dashboard temp gauge never showed overheating

Solved in this order.

1. Replaced coolant temp gauge. Dash gauge showed correctly. Still overheating.
2. Tested all fuses and relays. All worked. Still no fans working
3. Recharged AC.
4.Tested fan voltage with voltmeter. Here's where it got interesting:
a: attempted to separate one fan connector plug from the fan. accidentally jiggled plug, fan came on. finger nearly cut off. (engine was not running and no key in ignition).
b: bandaged finger (middle FU finger, of course)
c: removed negative battery terminal
d: removed fan connectors to test voltage. One connector (the fan that almost cut my finger off) had a burned connection. Male side of connector is on fan, female is plug. Charred and melted plastic on the plug, so it would not seat properly on fan.
e. replaced burned plug and tested fan with battery pack to ensure they worked. They worked.
f. believing problem solved, connected wiring back to fans.
g. One fan, the one with the originally burned connector, starts running as soon as negative battery terminal is reattached.

Issue of fans not turning on fixed.

New problem: Fan won't turn off as long as battery is attached. Ne engine running, no key inserted, just fan running on super high speed.

Solution: I had previously tested all of the relays and they opened when power was attached to them. On internet forum advise, I purchased a brand new relay and pulled them one by one to see if the fan would turn off. First two didn't turn off fan when pulled. Third relay turned off fan when pulled. Replaced that relay. All seems to be well.

Now no overheating
No continuous fan running when it shouldn't
All seems to be normal.

Thank you to everyone who has ever contributed to an internet forum on how to fix things on your car. It has saved me thousands of dollars over the years, and I have been able to teach my boys as well which will save them over their lifetimes as well. You are all much appreciated.
 

rockola1971

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One small problem....You charged your AC system with no fans drawing heat out of your condenser coil. You likely overcharged your system and will never know until your fans are running correctly and you let the system stabilize on high and THEN check refrigerant pressures.
 

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