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. my symptoms before were that the fans wouldnt turn on. i replaced the module and it ran great fans working at correct temperature everything, a month later my fans stopped working again. im about to buy another fan control module but has anyone had any issues like this? i find it hard to believe after 40k miles my fan module craps out twice. When i took my vette to the dealer they told me i needed programming for the part. it was 300$ so i opted not too but could that have caused my problems?
check the connector. There are numerous threads about the connector having a problem with the amount of amps that are pulled through it and it melts the connector. Most, including myself, just cuts the wires and bypass the connector.
Check the ZR1 forum for a thread or sticky by "whatcop?" that details how to bypass the OEM connector and wiring, to something that won't melt. I think he even lists the relays needed and has instructions on the install.
You don't have the fans set for 100% in the tune, do you? Max should be 95% or the melting could be a problem there too.
Someone used a Ford Crown Vic controller as a replacement for the D3 fan controller setup not too long ago, might be worth a quick search for that as well.
I also checked the GM service info, there is no fan control module programming necessary if replacing the module. Sounds like the dealer you went to may be mistaken (or trying to simply make a quick $300).