@Mooseman
That's one of the large fuses. The 'contacts inside the fuse box' are 2 male spades connectors. I did inspect them and the female spade connectors in the fuse and neither show any sign of getting hot. I also popped off the clear cap and pushed the element around with a probe to see if I could find a crack. I've had fuses physically break before and the crack could not be seen by the naked eye. The fuse also fits pretty tight, I can not remove it by hand. That doesn't necessarily mean both connectors are tight though. I'll pull it back out and test both sides with a different male spade connector.
I've now noticed that the problem is intermittent. Right after the first post here, I started the vehicle, set the temp sliders both all the way down (manual controls), turned on the AC and Recirc, then turned the fan to 5 and it ran fine. After a minute I switched the fan to 4 and back to 5 and it stopped.
A few minutes later I switched it back to 5 and it ran. I left it running on 5 a few mintues. Then I switched it back and forth between 5 and the other settings several times and it kept working.
Other then that, the HVAC works great. I've never had a vehicle produce hot or cold air so fast before.
![40a fuse.jpg 40a fuse.jpg](https://gmtnation.com/forums/data/attachments/169/169355-0241b040463f16ce7fcd61ae9b506a2c.jpg)