Well.... A friend came over today and said, "lets tackle this thing"
We retraced everything we could find that has a wire attached to it. took apart, tested, pushed, pulled, cussed and bled on, in, under or above this Tahoe.
For the life of us we could not find a sending unit beside the water pump, thermostat housing. Just doesn't seem to be there. The only sending unit we could find was above the #1 plug.
we disconnected all electrical for the A/C, and removed the relay and 10 amp fuse. cleaned all battery posts and checked all ground connections.
Everything we tested and tried was confirmed pointless by the test light we placed into the positive plug for the fan and grounded to batt. the light would just stay on, meaning we had not solved the fan on situation.
For a last attempt i said, well lets take out that wire connection for the PMC. this time we took it completely off the plug in. we looked it over, and as suspected, the whole thing looked spotless. no corrosion nor any sign that would make a person think a fault was there.
We replaced it all back up. re-hooked the battery and waited for the test light to come on .. and waited ... and waited ... AND WAITED ........
Nothing .... we looked at each other with that WTF expression ....
been 3 hours now, wife took the truck to town 2 hours ago and its been sitting for an hour now... still nothing .....
One thing is 100% for certain ... I am not holding my breath that it is fixed (been down that road) LOL If this shorts out again I will take out the #1 fan relay and I have a Flex-Lite probe and relay system new in package on the wall in the shop that i was saving for a project (but the fan I bought for it came with its own controller. so i will just bypass the Tahoe relay system and build my own fan controlling system.
this is to much work and effort...
cheers and fingers crossed.