Manual HVAC no Blower and No Sound to Boss Stereo?

Tiny
VESPAGUY
  • MEMBER
  • 2005 CHEVROLET TAHOE
  • 5.3L
  • V8
  • 2WD
  • AUTOMATIC
  • 300,000 MILES
Hello,

I have a 2005 Chevy Tahoe, with manual front/rear climate control that is not working for front and rear. The factory Boss stereo turns on but no sound from amp. I've put in a new Climate control module, new blower motor resistor and blower motor.

The red wire in the resistor wire was melted when I started the project.I just received this truck. The stereo sound came on after a day of working on replacing the HVAC parts, next day no sound. I noticed the HVAC control module lights were not coming on with vehicle lights and believe I have a bad ground that is common to the stereo/amp.

I've checked all fuses with a multimeter but I'm also new to using one. I've been looking at wiring diagrams. The common ground connecting wires near the A pillar ar ok from looking at it through the windshield, but the connector with 2 ground wires leading to it is deep under the dash near the windshield. I've been visually checking orange wires coming from both HVAC Module and stereo, as well as ground wires.

Any help would be appreciated.
Saturday, February 21st, 2026 AT 5:32 PM

3 Replies

Tiny
VESPAGUY
  • MEMBER
  • 3 POSTS
I've attached a picture of the old plug. I've replaced it with the harness that came with a new Blower Motor Resistor
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Sunday, February 22nd, 2026 AT 5:02 AM
Tiny
VESPAGUY
  • MEMBER
  • 3 POSTS
This is the replacement blower motor resistor plug, picture was taken when checking Oms.
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Sunday, February 22nd, 2026 AT 5:37 AM
Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 54,902 POSTS
Good find and repair on the melted wiring. Lets start by double checking the power to the resistor plug (red wire) should have 12 volts when the key is on. Next, with the system on check the black wire (e) for power, if any is present the ground is bad. Let me know what you find and we can go from there. Check out the images (below). Please let us know what happens.
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Sunday, February 22nd, 2026 AT 7:49 AM

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