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Common Sense + Critical Thinking
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Discussion Starter · #1 ·
The Blue Beast was found 70miles away on craigslist, a blue 2003 Safari AWD with just under 230,000miles on it.
I figured what the heck, another 3rd gen would be a good investment even if only for parts.
Didn't want to low ball the guy, so I was packing up my tools and put my cardboard away when the guy offered for me to take it at a very reasonable price, so I countered with $50 less and he accepted.

Pros:
It was cheap
Drove all the way home without issue
Engine/transmission runs/shifts well
A/C works
Tires are good
Cheap purchase price
New alternator, new fuel injector spider
Liftgate works
No rust!
Included trailer hitch and ball
Seats in the back look good
Did I mention that it was cheap?

Cons:
Loud growl from the front differential, haven't even bothered looking at it yet probably deserves a steel cased differential in there anyway.
External coolant leak
No communication from EBCM
PS PDL and handle don't work
Drivers side mirror smashed and mostly gone.
Blower doesn't run on high
Rear differential worn.
Front DS&PS seats are worn, recliner handle stripped. Floppy DS armrest.
Parking brake needs adjusting/repair
Paint isn't perfect
Needs a good cleaning

Photos are as it was picked up.
 

· Administrator
Common Sense + Critical Thinking
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Discussion Starter · #4 ·
jimi_lee said:
Welcome to the board. We like pics.
Thanks, feels good to be here, hope I can be of help ;)

:text-worthless:
Will probably update the first post tomorrow with some pictures. Pictures Added!
 

· Super Moderator
05 Astro AWD
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14,399 Posts
:rofl:

Will - if you want a CD player that works, I've got one or two here :lol:
 

· Administrator
Common Sense + Critical Thinking
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Discussion Starter · #10 ·
Leeann_93 said:
Will - if you want a CD player that works, I've got one or two here :lol:
Thanks for the offer. I have one sitting in a box in the garage, just haven't added an AUX input to it yet.

Lubed up the hood/doors/latches today, well overdue.

Decided to look at the blower motor today while I had a few minutes. First pulled the 30a fuse that supplies the high speed side. That was good, so I pulled the coolant recovery/washer fluid tanks and took a look at the connector. It's burnt to a crisp.
 

· Registered
1992 Astro - Silver / Gray / 4 Wheels
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6,157 Posts
AstroWill said:
jimi_lee said:
Welcome to the board. We like pics.
Thanks, feels good to be here, hope I can be of help ;)

:text-worthless:
Will probably update the first post tomorrow with some pictures. Pictures Added!
Nice Van, hopefully a good buy $$ and some really great posts there!!

Mike
 

· Administrator
Common Sense + Critical Thinking
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14,572 Posts
Discussion Starter · #13 ·
Leeann_93 said:
Oh, my favorite repair.
Parts are ordered, should be done by the end of the week.

Swapped out the radio from the white 03 POS, as it already has the aux input that I did here https://www.astrosafari.com/viewtopic.php?f=32&t=23577. I did replace the broken buttons on the front a while back. The one I had in the garage was a tape player with remote CD, threw that into the POS. It's amazing how fast you can swap out a radio on these, took me longer to dig it out of the garage.

Also swapped out the DS mirror from the POS.
 

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Common Sense + Critical Thinking
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Discussion Starter · #14 ·
Here was the problem with my front blower motor.
The high speed relay is built into the resistor pack/blower control. See pictures and more info on the HVAC system here: Astro-Safari-Info - HVAC Airflow
$15.75 blower motor resistor connector https://amzn.to/3dOFIqk
$13.66 blower motor resistor https://amzn.to/3nsbwob
Delco blower motor if you need it https://amzn.to/3qj8oNT

Ended up with a burnt blower motor controller connector

Broke this support while trying to remove it. Used to clip into this hole.

About 14inches from the connector, will try to find a replacement one of these days.

Above is the old blower motor controller.

Soldered and heat-shrinked the new connector on, it's generic so all of the wires are 12awg.

Bent the pins back so that I didn't have to trim the housing for the new blower motor controller to fit.

New blower controller and connector installed and connected, working perfectly. Now high works again.

Finished up by replacing the windshield washer and coolant tanks.


While I didn't need to replace the blower motor on this one yet, if yours requires a blower motor replacement, here is a good thread on replacing the blower motor: The Blue Beast 2003 AWD Safari
 

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Common Sense + Critical Thinking
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Discussion Starter · #15 ·
Here is the radio that I swapped out from my 03POS. Probably will switch this out to a DoubleDIN navigation radio in the future. But it will work while I decide which model I want to install.

Also repaired the armrest this morning. GM says to use internal snap-ring pliers, I used a screwdriver.

Will probably use the Metra double din 2DIN kit once I decide which HU I want to use.
Without the wiring harness https://amzn.to/332TXj4

With the wiring harness and antenna adapter https://amzn.to/33d6EYR
 

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Common Sense + Critical Thinking
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Discussion Starter · #16 ·
Just been driving it around town, still has a coolant leak that I haven't fixed yet.

Getting ready to put it up on jack stands to swap out the front differential from the white POS. Would have been really, really cool if they had used flanges on the front differential.
 

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Common Sense + Critical Thinking
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Discussion Starter · #18 ·
AstroWill said:
Cons:
Loud growl from the front differential, haven't even bothered looking at it yet probably deserves a steel cased differential in there anyway.
Decided not to go with the cast front differential. It's ~$100 at the junk yard but I don't think that I will ever really need a locker in the front. If I change my mind I will go through all of the work again.
 

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Common Sense + Critical Thinking
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Discussion Starter · #19 ·

· Administrator
Common Sense + Critical Thinking
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Discussion Starter · #20 ·
Oh yea, will be glad to get this out of the garage as well.

The 4wd transfer case(and electronics(not in the picture(yet))) to go into the Blue Beast.

 
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