3-Hour Battery change

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KC 2013 Tahoe

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Spent most of yesterday evening battling gremlins following replacement of the battery in my bride's '13 Tahoe LTZ

This weekend, it had started giving the tell-tale signs that this summer's record, long 110+ heat finally exacted its toll.
Weak/slow cranking and a new dash warning: "Battery Voltage Low, start engine immediately".
Verified the system was indeed charging with DVM. At idle measured 14.55 to 14.65 Volts.

OK, so no biggie, picked-up a replacement at Costco on way home from work yesterday. Following dinner went out and spent the obligatory 20-30 minutes removing the old battery, cleaning all the terminals, battery posts and 145Amp Fuse on positive cable end to a shiny finish, carefully re-connecting everything and finally snugging-down the battery hold-down block/nut. They were pretty clean to start with, but I always do this when changing a battery.

Was rewarded with a robust crank of the starter and the engine roaring to life with renewed vigor... along with a repetitive clicking sound from behind the RR interior plastic trim panel that wouldn't stop unless turning-off the ignition. Also a new warning message I've not seen before... more on that one shortly.
I know the guts for the rear HVAC are behind that panel, so thinking one of the servos is whacked. Tried disconnecting the battery again, waited 10 minutes and reconnected, only to be met with the same result. Drove it around the block to see if it would cease but no-bueno. Pulled over and shut the engine off, then cycled the ignition key off/on several times, noting the clicking got slower each time I cycled the ignition. After about 7 additional tries, it finally stopped... yeah!

Pulled into driveway and now decided to checkout the new warning message: "Parking Assist is blocked, see owners manual" WTF?!!
Shut it all off, got out my code reader, plugged it in and started her up only to meet with that infernal clicking sound again.
BTW - readout was all clear, 0-codes, 0-codes pending.

Grabbed owner's manual out of glovebox and read through it at kitchen table. The sage advice regarding the Parking Assist warning it offered was to take it to dealership to be looked at. Nope. Not going down that road. Will dig into it later, as it's not affecting driveability or being a nuisance.

Googled: "clicking noise after changing battery: 2013 Tahoe" and oh my... seems I have lots and lots of company on this one!
Seems there's a rear HVAC blend door and air level actuator with gears made of the same poor-quality plastic as on this vehicle's:
1) Power folding mirrors: (had already replaced both sides with Gruvenparts new motors and metal gears)
2) Inner front door pulls RH and LH: replaced LH with Dorman repair kit, RH w/OEM GM door panel
3) LR and RR Window regulators: brittle/shattered white plastic frames (replaced both with Dorman)
4) Outer Door handles all four of them: broken plastic pivots/anchors in all of them (again - Dorman to the rescue)

As it was now 10:15PM decided I'd try adjusting the temperature and Heater-A/C function settings to see if one of the servos had perhaps landed on a dead spot/split on the gear. Adjusted the temperature up/down a couple degrees and the noise finally stopped and hasn't come back. Going to pull panel and replace both servos over the long holiday weekend, but considering that OK for now. Yeah #2!

After restarting and pulling into the garage for the night, realized the Parking Assist warning miraculously cleared itself, so yeah! #3.

To close:
In my searches last night, came across a GM website hyping their quality:

To me their statement is outright insulting and borderline delusional:
"Rigorous testing. Renowned durability. At GM, we’re focused on engineering high-quality, durable and reliable products that hold up to the every day."

No quality-oriented company would design these items with cheap plastics that harden and shatter over time.
My wife (Science Teacher) commutes in her Tahoe to/from her school on paved roads every day.
She's not off-roading, driving through construction sites or roaring at high speeds down gravel roads.

IMHO: These components were designed to fail, pure and simple.

I'd encourage GM to respond to this, but I'm rather certain it'll be about how their materials selections are responsibly sourced globally from a diverse supply chain, to optimize vehicle fuel economy and ownership value.
 
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