Bulletin No.:

Service Bulletin

Date:

19-NA-099
August, 2019

TECHNICAL
Subject:

Add-On Equipment Inoperative, Melted Terminals on Auxiliary Relay, New Auxiliary
Battery Relay for Police Tahoe Vehicles

Attention: This bulletin only applies to the Police Patrol Vehicles (PPV).
Brand:

Model:

Chevrolet

Tahoe PPV

Model Year:

VIN:

from

to

2015

2019

Involved Region or Country

from

Engine:

Transmission:

All

All

to

North America, N.A. Export Regions

Additional Options (RPOs)
Condition

Customer may comment on add-on equipment inoperative or possibly seeing melted
terminals on the auxiliary battery relay.

Cause

The cause of the condition may be overheating of the relay during charging the auxiliary
battery.

Correction

5333969

Replace the original relay with new relay service part, shown in the graphic above. The
new relay is more heat tolerant and should resist melting and losing electrical contact.
Refer to the Service procedure below.

Copyright 2019 General Motors LLC. All Rights Reserved.

Page 2

August, 2019

Bulletin No.: 19-NA-099

Service Procedure
1. Open the hood.
2. Before starting any repairs, disconnect the main
battery ground cable AND the auxiliary battery
ground cable, from the battery ground terminals.

5333964

6. Install the new relay (1) on the existing mounting
studs on the bulkhead, and reinstall the 2
factory nuts.

Tighten
5333956

3. Disconnect the 2-way connector (1) from the
battery relay, located on driver side bulkhead.

Tighten the nuts to 9 Y (80 lb in).
7. Install one piece of 1/4” dia. convoluted tubing
loom (2), on the exposed section of battery cable,
to be installed on the passenger side stud of the
new relay.

5333959

4. Remove the 2 factory nuts (1) and the existing
battery relay from the bulkhead.
5. Disconnect the 2 battery cables (2) going to
existing battery relay on the vehicle bulkhead.

5333965

8. Install the battery cable coming from the main
battery to the passenger side stud (1) of the new
relay.
9. Install the battery cable coming from the auxiliary
battery to the driver side stud (2) of the new relay.
10. Make sure the cable orientation is as shown in the
above graphic, with adequate strain relief.

Bulletin No.: 19-NA-099

August, 2019

Page 3

Important: Ensure the boots are fully seated over the
power studs.
12. Install the rubber boots (2) over the relay battery
studs, to protect both studs.
13. Connect the relay 2 - way connector to the vehicle
harness, mating the 2 – way connector previously
disconnected from the old relay.
14. As shown in the graphic above, secure the
connector to the passenger side battery cable
previously loomed, with one cable tie (3).
15. Re-connect the ground cable to the auxiliary
battery ground terminal.
16. Re-connect the ground cable to the main battery
ground terminal.

Parts Information
Causal
Part

Description

Part
Number

Qty

X

RELAY ASMAUX BAT

84611502

1

5333967

11. Tighten battery cable studs (1) to torque.

Tighten

Warranty Information

Tighten the studs to 7.5 Y (66 lb in).

For vehicles repaired under the Bumper-to-Bumper
coverage (Canada Base Warranty coverage), use the
following labor operation. Reference the Applicable
Warranties section of Investigate Vehicle History (IVH)
for coverage information.

Labor Operation

Description

Labor Time

4086968*

Auxiliary Battery Relay Replacement

0.2 hr

*This is a unique Labor Operation for Bulletin use only.

Version

1

Modified

Released August 06, 2019

GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these
technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper
service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a
job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your
vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the
information.

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