2002 GMC Sierra
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › GMC › Sierra › 2002
These records cover every 2002 GMC Sierra. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
7 recalls name the 2002 GMC Sierra. Newest first.
Dope, inc. IS recalling 42,540 combination corner and bumper lamp assemblies of various part numbers sold for use as aftermarket equipment for various passenger vehicles. these headlamps fail to conform to the requirements of federal motor vehicle safety standard no. 108, "lamps, reflective devices, and associated equipment." these lamps do not contain…
Risk and remedy
Risk
Decreased lighting visibility may result in a vehicle crash.
Remedy
Dope, inc. Will notify owners and offer a full refund for the noncompliant combination lamps. the safety recall began on july 28, 2009. owners may contact dope, inc. At 1-626-272-1798.
Certain cequent 90 degree 7-WAY right angle adaptors sold by distributors in tow packages for aftermarket sales to tow 5TH wheel rv travel trailers. due to incorrect wiring of the harness, the trailer lights may not operate properly.
Risk and remedy
Risk
If the trailer lights are not working properly, a vehicle crash can occur.
Remedy
All of the defective tow packages are still at the distributor level and have not been sold to any consumers.
Certain pickup trucks and sport utility vehicles may experience unwanted antilock brake system (ABS) activation. this condition IS more likely to occur in environmentally corrosive areas. this recall will be launched in the "salt belt" states of connecticut, delaware, illinois, indiana, iowa, maryland, massachusetts, maine, michigan, minnesota, missouri…
Risk and remedy
Risk
This can cause increased stopping distances during low-speed brake applications, which could result in a crash.
Remedy
Dealers are to remove the wheel speed sensor and thoroughly clean the wheel speed sensor mounting surface on the bearing, apply rust inhibitor to the cleaned surface, grease the mounting surface, reinstall the wheel speed sensor, and check the peak-to-peak output voltage to ensure the wheel speed signal IS within specifications. the recall began september 22, 2005. owners may contact chevrolet at 1-800-630-2438 or GMC at 1-866-996-9463.
On certain pickup trucks equipped with manual transmissions and built with either pbr parking brake systems or trw parking brake systems, the parking brake friction linings may wear to an extent where the parking brake can become ineffective in immobilizing a parked vehicle.
Risk and remedy
Risk
If the parking brake does not hold, unintended vehicle movement could occur, which could result in a crash.
Remedy
Dealers will install a low-force spring clip retainer for vehicles equipped with a pbr parking brake system. on vehicles equipped with the trw parking brake system, dealers will install a redesigned parking brake cable assembly. the recall began on july 29, 2005. owners may contact chevrolet at 1-800-630-2438 or GMC at 1-866-996-9463.
Aftermarket pickup truck over-the-rail bedliners manufactured for installation on 1999-2004 chevrolet silverado and GMC sierra pickup trucks. the toggle wing assembly used to attach the bedliner to the truck bed IS not engaging fully in the stake pocket of the pickup truck.
Risk and remedy
Risk
The bedliner can become detached from the pickup while it IS motion, possibly endangering following motorists or pedestrians.
Remedy
Durakon will issue a press release in attempt to notify customers that could have purchased the defective bedliner. if you purchased either a durakon allstar of patriot overrail bedliner since august 1, 2003, for 1999 to 2004 chevrolet silverado or GMC sierra trucks, or purchased one of these pickup trucks with either brand bedliner already installed, you should return to an authorized durakon dealer so that the bedliner can be inspected and, if necessary, repaired with a newly designed toggle wing fastening system, or if required, replaced with a new bedliner free of charge. please call the durakon hotline at 1-800-933-4200 to find the nearest authorized durakon dealer.
On certain pickup trucks and sport utility vehicles, the galvanized steel tailgate support cables that retain the tailgate in the full open (horizontal) position may corrode, weaken, and eventually fracture. if both cables fractured, the tailgate would suddenly drop and strike the top surface of the rear bumper.
Risk and remedy
Risk
Anyone sitting or standing on the horizontal surface of the tailgate when both cables fractured could be injured by falling from the tailgate. on vehicles that have had the bumper removed, the tailgate may drop even lower. additionally, if there IS cargo on the tailgate the cargo may fall off if the support cables fracture.
Remedy
Dealers will replace the cables. interim owner notification began on april 7, 20004. the recall began on september 24, 2004, when replacement parts were available, and will continue through october 29, 2004. owners should contact cadillac at 1-866-982-2339, chevrolet at 1-800-630-2438 or GMC at 1-866-996-9463, or visit www.mygmlink.com, and enter your vehicle identification number.
Some 2WD and 4WD pickup trucks, converted to either dedicated or bi-fuel compressed natural gas (CNG) fuel usage, were assembled with a throttle cable that can contact and rub through the flexible pressurized fuel line creating a pinhole leak of natural gas to the atmosphere.
Risk and remedy
Risk
A strong odor of natural gas may be detected from inside the vehicle, possibly accompanied by a hissing noise. if the natural gas were accidentally ignited, serious injury could result.
Remedy
Dealers will secure the throttle cable to eliminate the possibility of contact with the CNG fuel line. the CNG fuel line, throttle cable, and cruise control cable are also to be inspected and replaced if necessary. owner notification began on december 11, 2003. owners should contact chevrolet at 1-800-630-2438 or GMC at 1-866-996-9463.
Owner complaints
249 complaints23 involved a crash2 involved a fire6 injuries
What owners report most
Latest complaints
- Service brakes
TL* the contact owns a 2002 GMC sierra. While driving 45 mph, the brake pedal was depressed, but the vehicle failed to stop. The contact veered into a ditch to avoid a collision. The vehicle was towed to an independent mechanic who diagnosed that the brake lines were corroded and needed to be replaced. The vehicle was repaired. The manufacturer was not notified of the failure. The failure mileage was 100,000.
- Engine
TL* the contact owns a 2002 GMC sierria. The contact received notification of nhtsa campaign number: 15v201000 (engine and engine cooling); however, the part needed to perform the repair was unavailable. The contact stated that the manufacturer exceeded a reasonable amount of time for the recall…
TL* the contact owns a 2002 GMC sierria. The contact received notification of nhtsa campaign number: 15v201000 (engine and engine cooling); however, the part needed to perform the repair was unavailable. The contact stated that the manufacturer exceeded a reasonable amount of time for the recall repair. The manufacturer was notified of the issue. The contact had not experienced a failure. Vin tool confirms parts not available.
- Unknown or other
On two separate occasions over the past few years, this truck has had frame damage caused by rust / corrosion to the extent that it either would not pass inspection or it compromised the operation of the vehicle. more specifically, the frame cross-members have had holes rotted through them and the…
On two separate occasions over the past few years, this truck has had frame damage caused by rust / corrosion to the extent that it either would not pass inspection or it compromised the operation of the vehicle. more specifically, the frame cross-members have had holes rotted through them and the shock mounts have rotted from the frame. presently, the two cross-members that go over the fuel tank have large rust holes over the fuel tank. also, the rear crossmember has rotted areas on the top left side.
- Service brakes
On the morning of friday august 21, 2015, my wife went to move my 2002 GMC sierra. She pulled out of our driveway and proceeded up-hill about 300-400 feet, and then turned around in a neighbor's driveway, when coming back down the hill she tried to brake to stop in front of our house, but the…
On the morning of friday august 21, 2015, my wife went to move my 2002 GMC sierra. She pulled out of our driveway and proceeded up-hill about 300-400 feet, and then turned around in a neighbor's driveway, when coming back down the hill she tried to brake to stop in front of our house, but the brakes totally failed without any warning. She then went up a slight hill on the other side of our house, but still couldn't stop, and didn't think to put the truck in park as she slowed. She rolled backwards down the hill and was able to steer into a neighbor's yard where the truck came to rest on a berm. at the time she said there were cars parked on both sides of the street and had a car been coming the opposite direction she would have crashed into it. Had there been pedestrians they could have been hit as well. When I came home that afternoon, I added brake fluid to the reservoir, and then pushed on the brake pedal. I saw a huge stream of fluid pour from below the driver's side door. I looked under the truck and found the brake lines surprisingly corroded. If sudden, immediate loss of brakes without any warning IS not cause for a recall I do not know what IS.
- Service brakes
Left house and ABS brake light came on, shut the truck off and ABS brake pump under truck would not stop running even with key off. So had to take fuse out. At that time I drove back home, but if you push down on brake it will go to the floor. June 2014 had truck in shop to have all brake lines…
Left house and ABS brake light came on, shut the truck off and ABS brake pump under truck would not stop running even with key off. So had to take fuse out. At that time I drove back home, but if you push down on brake it will go to the floor. June 2014 had truck in shop to have all brake lines replaced and fixed at auffenberg in carbondale illinois due to brakes all of a sudden going out and all lines rusted and now 2,500 miles later this happens also the emgerency brake IS not working either. So was there more damage done from all this that should be on recall and us not paying the bill for these defects.
- Engine
The passenger side rear exhaust manifold bolt broke off. this IS a manufacturer defect. this IS a very common problem with these trucks.
- Service brakes
Applied brakes to stop and brake peddle went to floor do to rotted brake line. *tr
- Steering
TL* the contact owns a 2002 GMC sierra. While driving 60 mph, the wheels went in a different direction than the steering wheel. The vehicle was not diagnosed or repaired. The manufacturer was notified of the issue, but there was no response. The approximate failure mileage was 216,000. updated 7/14/15*cn the consumer was informed the parts were no longer available to fix the problem. Updated 07/30/15*jb
- Service brakes
Made a left hand turn at a traffic light after it turned green. I was the only vehicle at the time making the turn, nobody in front or behind me. Drove about 1/10th a mile to the next light, when it turned yellow, I immediately hit the brakes to stop. At first the brakes worked then my foot went to…
Made a left hand turn at a traffic light after it turned green. I was the only vehicle at the time making the turn, nobody in front or behind me. Drove about 1/10th a mile to the next light, when it turned yellow, I immediately hit the brakes to stop. At first the brakes worked then my foot went to the floor, I had no brakes. I came to a stop in the middle of the intersection. I then backed up, to get behind the light. As I stated at the beginning, there was nobody in front or behind me at the other light making the turn with me, so when I was approaching the next light, I had nobody in front of me, behind me or to my right. The roadway was four lanes, two in each direction, with a center medium. I was driving in the left lane. So I am looking to drive another day and someone else too. The cause of the problem IS that the brake line that goes from the front to the rear, running along side the frame, on the driver side, rusted out and broke. I contacted gm about this, and after talking and complaining about what happened, they said there was nothing they could do for me. my problem IS that, this IS a safety issue, and they take no responsibility for it. I should have been at least notified in some way as an owner that my life may be in danger if I do not have my brake lines checked and replaced if needed. They no about the problem and are not contacting owners of my vehicle and others with the same problem. I am looking to have not been hurt or killed or hurting and killing someone else. I did not know of the problem until after it happened. I am now faced with doing the work myself, which IS a major undertaking, or having the local GMC dealership doing it for 1500+, which IS where it IS right now, waiting for my call. Thank you. *tr
- Service brakes
Started vehicle and began driving on street. brake pedal went to the floor and brakes were not normal. stopped vehicle and saw large puddle of brake fluid under vehicle. had vehicle towed to repair shop and was told brake line rusted and all brake lines were corroded and that gm has had problems…
Started vehicle and began driving on street. brake pedal went to the floor and brakes were not normal. stopped vehicle and saw large puddle of brake fluid under vehicle. had vehicle towed to repair shop and was told brake line rusted and all brake lines were corroded and that gm has had problems with this in many vehicles. Fortunate that failure had not occurred at highway speeds. repair estimate was $3200 for replacement of brake lines and associated parts. *tr
- Fuel/propulsion system · Service brakes
Dear sir or ma'am, I have a 2002 GMC sierra truck that I bought new in 2002. The brakes recently failed completely while my wife was driving on or about september 26, 2014. The brake pedal went to the floor without significant braking action. fortunately she was able to stop safely and was not…
Dear sir or ma'am, I have a 2002 GMC sierra truck that I bought new in 2002. The brakes recently failed completely while my wife was driving on or about september 26, 2014. The brake pedal went to the floor without significant braking action. fortunately she was able to stop safely and was not involved in an accident. Upon examination, the brake line to the left rear wheel was completely rusted through. I examined the rest of the lines and noticed that the brake lines, the transmission cooler line and the fuel line all show signs of major corrosion, especially along the frame. I have less than 43,000 miles on this truck and it was garage-kept the first nine years I owned it. I live in ky where the roads are only salted a few times a year. The rest of the vehicle IS relatively rust free. The truck IS unsafe to drive now. Even if I patch the leak, the rest of the lines could fail at any time. I could suffer catastrophic brake failure while towing my boat or horse trailer or simply going down a hill. Furthermore, the fuel lines are under considerable pressure and if they rupture, there could be a very dangerous fire hazard. If the transmission cooler lines rupture, I could have a complete transmission failure. I have read that this IS a known issue with chevrolet and GMC trucks for years 1999 to 2003 and that the nthsa has looked into this in the past. if other trucks are in the same condition as mine (and I believe there are), there IS a major safety problem on the roads right now. Yet, to date no recall has been issued. I think this IS courting disaster. It IS my opinion that lines made with inferior steel were used in the construction of this vehicle, yet gm refuses to acknowledge the fact. I urge you to look further into this matter. this IS nthsa case number: [xxx] information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(B)(6). *tr
- Electrical system
Folks; what IS the story with tin whiskers forming in soldered electrical components? does my GMC have lead free solder anywhere in it's electrically soldered components? I've have multiple failed electrical systems which implies multiple shorts. what makes, models and years are this problem known to have occurred in besides the toyota camry 2003? what are you doing to fix this problem? *tr
- Service brakes
TL* the contact owns a 2002 GMC sierra 1500. the contact stated that while traveling 55 mph, the brake pedal sank abormally into the floorboard and failed to stop the vehicle. The brake light illuminated on the instrument panel. the vehicle was merged to the side of the road where the vehicle was…
TL* the contact owns a 2002 GMC sierra 1500. the contact stated that while traveling 55 mph, the brake pedal sank abormally into the floorboard and failed to stop the vehicle. The brake light illuminated on the instrument panel. the vehicle was merged to the side of the road where the vehicle was turned off and restarted. the manufacturer was not notified. The vehicle was taken to an independent mechanic. The technician diagnosed that the brake lines needed to be replaced. the failure and current mileage was 127,000.
- Service brakes
I was driving approx 35 mph when a dog ran in front of my vehicle. I applied the brakes to avoid hitting the dog. A moment later I went to apply brakes to slow down for an unfamiliar turn and my pedal went to the floor. I managed to downshift to come to a stop and upon inspection, noticed a hole in…
I was driving approx 35 mph when a dog ran in front of my vehicle. I applied the brakes to avoid hitting the dog. A moment later I went to apply brakes to slow down for an unfamiliar turn and my pedal went to the floor. I managed to downshift to come to a stop and upon inspection, noticed a hole in my drivers side rear brake line. All of the brake lines have a severe amount of rust. The bundle of lines running along the frame on the driver's side are the worst. *tr
- Service brakes
When IS there going to be a recall on the rusted brake lines, I already crashed in 2006 with the ABS system which failed and was a failure to start with and when they fixed, the fix only lasted for 14 months and since then I have be driving with conventional brakes,so are they waiting for me and others to crash again with these rusty brake lines. P.s. Going on 3RD. Set of rotors in the rear, only 65,000 mi. *tr
- Service brakes
Xmas tree shopping w/family very long stopping distance, then no brakes. I made repair at holding bracket near left front wheel on frame. Then on 2/25/2014 another brake line rust failure near but in back of ABS module to back wheels. I replaced that section . Today 3/15/2014 another failure at the…
Xmas tree shopping w/family very long stopping distance, then no brakes. I made repair at holding bracket near left front wheel on frame. Then on 2/25/2014 another brake line rust failure near but in back of ABS module to back wheels. I replaced that section . Today 3/15/2014 another failure at the first spot,holding bracket near left front wheel on frame. All this on 2002 GMC sierra,funny I have a 2002 ford taurus almost the same mileage no brake problems. *Tr
- Service brakes
I was slowing to a stop light from residential street,into a main road, and brake pedal went to the floor. I pumped brakes and recovered pressure and stopped. I then proceeded on the main road to next light. After being at the light with my foot on the pedal for approx. 15 sec. The pedal went to…
I was slowing to a stop light from residential street,into a main road, and brake pedal went to the floor. I pumped brakes and recovered pressure and stopped. I then proceeded on the main road to next light. After being at the light with my foot on the pedal for approx. 15 sec. The pedal went to the floor and truck began rolling forward. I let pedal go and pumped and pressure came back and held for about 15 more sec. Then failed again with truck rolling forward. I then drove the truck directly to the shop about 4 miles away. I was informed that a very alarming and common occurrence with 99-06 gm trucks occurred. my brake lines had rusted out completely. 650.00 bucks later I'm back on the road. I was told to look at this site and I was amazed at how many other vehicles have reported this problem. I was wondering if gm would be so kind as to at least pick up the cost of the parts which I was told around 100.00. wishful thinking I guess. *tr
- Service brakes
Brake line burst when brakes were applied. according to multiple repair facilities all brake lines are extremely rusted and must be replaced. rear brake components also rusted and must be replaced. cost of repairs exceeds $3000.00. I've had several vehicles the same age ( with more miles ) that…
Brake line burst when brakes were applied. according to multiple repair facilities all brake lines are extremely rusted and must be replaced. rear brake components also rusted and must be replaced. cost of repairs exceeds $3000.00. I've had several vehicles the same age ( with more miles ) that don't have nearly the same amount rust even though they too have spent their winters in michigan. stopping a vehicle has to be the most important aspect of a vehicle to get correct. how IS it that manufactures are not required to use the best product available for brake lines? *tr
- Service brakes
Driving 30 mph in traffic. Light turns red . Cars in front of me apply brakes .i applied my brakes. Brakes instantly felt spongy and abnormal. Applied more pressure with 2 feet and brake pedal went to the floor with no warning at all. No brake light on dash came on just went to floor. Was…
Driving 30 mph in traffic. Light turns red . Cars in front of me apply brakes .i applied my brakes. Brakes instantly felt spongy and abnormal. Applied more pressure with 2 feet and brake pedal went to the floor with no warning at all. No brake light on dash came on just went to floor. Was determined by my mechanic that the brake lines had rotted and I had a catastrophic brake failure loosing major brake fluid at the accident site. *tr
- Service brakes · Structure › Body
The accident happened in a parking lot. As I was turning at the end of row of parked vehicles ,a pick-up truck was backing out of a parking place. I applied the brakes but there was no response only a ratcheting noise coming from the front end of my pick-up. I put the truck in neutral but it…
The accident happened in a parking lot. As I was turning at the end of row of parked vehicles ,a pick-up truck was backing out of a parking place. I applied the brakes but there was no response only a ratcheting noise coming from the front end of my pick-up. I put the truck in neutral but it continued to go forward until my truck ran into the other one. This happened at a very low speed but there was still quite a bit of damage to the trucks. It almost felt like the truck was being pulled forward on its own. I got my truck in to a mechanic and he replaced the left front wheel speed sensor. This accident was small but I could just as easily run into someone in a wheelchair or someone that could not get out of the way. I found out later that the truck was recalled before I owned it (at 43000 miles) for the same problem. The truck now has 103000 miles on it and it appears that the original problem has not been solved. *tr
- Service brakes
The rear brake line failed when trying to stop for a red light. the brake pedal went to the floor and I was not able to stop the truck before entering the intersection. fortunately, there was no traffic crossing the intersection at the time. I got the truck home, and a puddle of brake fluid formed in the rear of the truck. upon inspection, all of the brake lines are badly corroded. *tr
- Service brakes
I have a 2002 GMC sierra and just pulled out of my driveway going down the street to stop sign and brake peddle went all the way to the floor causing me to go thru stop sign. Lucky no one was going the other way! managed to make it back home and noticed driveway all wet .looked under truck and…
I have a 2002 GMC sierra and just pulled out of my driveway going down the street to stop sign and brake peddle went all the way to the floor causing me to go thru stop sign. Lucky no one was going the other way! managed to make it back home and noticed driveway all wet .looked under truck and noticed the break lines all rotted! I cant believe that general motors would make steel brake lines knowing that steel will rot !did they just figure that out? I thought they should know better!!!! Why don't I here about other vehicle makes don't have this problem. Did they just learn about steel? This IS and important safety item and breaks need to work all the time. I also noticed the my fuel lines are showing the same signs. gm should repair and learn from this bad choice to install inferior equipment for such an important system in any vehicle. I have since repaired my break lines at a very expensive $1,500 ! *tr
- Service brakes
Brakes failed in drive way due to corroded line on top of frame rail under drivers seat. *Tr
- Service brakes · Structure › Body · Suspension
This IS an old incident; however, until just recently, I did not realize there was a website such as yours. also, I am reporting a specific incident, but also want to include other general information. the incident which occurred was related to my brake fluid lines rusting completely through…
This IS an old incident; however, until just recently, I did not realize there was a website such as yours. also, I am reporting a specific incident, but also want to include other general information. the incident which occurred was related to my brake fluid lines rusting completely through while I was driving down the road with my two small grandchildren. when a vehicle stopped in front of me, I pushed on my brakes only to find I could not stop. fortunately, there was a field on the right side of the road and I drove into it, rather than hitting the vehicle. when my husband checked the brakes, the lines literally fell apart. we still have this truck, but the entire underside of it (frame, spring hangers, front drive shaft, etc) are all rusted. another issue that happened earlier this summer - the spare tire carrier had become so rusted, my spare tire actually came lose while driving down the road. fortunately it was held up by a chain. upon learning that this IS a problem with most all gm trucks, I felt obligated to base my complaint in the hopes that something can be done. toyota faced similar problems, but fortunately stood behind their products and made it right with their customers and I feel gm should be required to do likewise. we have tried to trade this truck in for another vehicle, but are being offered way below kelly blue book price because of the rust issue. *tr
- Service brakes
As many other gmc/chevrolet truck owners, I am experiencing premature brake line rust issues. Luckily I was not involved in an accident, but a rusted brake line failed coming to an intersection. When the brake pedal was pushed, I felt a slight resistance and the brake pedal went straight to the floor. *tr
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Brake line corrosion failure
The Office of Defects Investigation (ODI) received Defect Petition DP10-003 on March 2, 2010, requesting the investigation of model year (MY) 2003 Chevrolet Silverado 2500HD 4WD pickup trucks for corrosion failures of the vehicle brake lines.DP10-003 was granted and on March 30, 2010, Preliminary Evaluation PE10-010…
The Office of Defects Investigation (ODI) received Defect Petition DP10-003 on March 2, 2010, requesting the investigation of model year (MY) 2003 Chevrolet Silverado 2500HD 4WD pickup trucks for corrosion failures of the vehicle brake lines.DP10-003 was granted and on March 30, 2010, Preliminary Evaluation PE10-010 was opened on more than six million model year 1999 through 2003 light trucks and sport utility vehicles manufactured and sold by General Motors Corporation (GM).On July 2, 2010, ODI received GM's response to an information request, which included GM's assessment of the frequency and safety consequences of the alleged defect. GM stated that:(1) the brake system of the subject vehicles is split front/rear and should a brake pipe suddenly fail for any reason, the affected vehicle would be capable of stopping with the pressure supplied by the remaining circuit; (2) the subject vehicles were designed to meet the hydraulic circuit partial failure requirements of Federal Motor Vehicle Safety Standards 105 and 135, Light Vehicle Brake Systems; and (3) should a brake fluid leak occur for any reason, the brake system malfunction indicator lamp (MIL) would illuminate and warn the driver before the brake fluid level was low enough to cause a loss of line pressure.ODI's and GM's analysis indicates that 85 percent of the complaints occurred on vehicles used primarily in States that use salt on the roads during Winter months (Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia and Wisconsin).Overall the complaint rates per 100,000 vehicles for Salt Belt States is 43.0 and Non-Salt Belt is 3.0.In approximately 25 percent of the complaints the brake pipe failure occurred suddenly, with no warning (i.e., no MIL, Brake Fluid Loss Warning), and resulted in extended stopping distances.In 30 of these the increase in stopping distance that resulted was a factor in the crash and in 10 others the vehicle was intentionally steered off the road or into another lane of travel in order to avoid a crash.This investigation has been upgraded to an Engineering Analysis (EA11-001) for subject vehicles sold or currently registered in Salt Belt States to further assess the scope, frequency and safety risks associated with sudden failures of corroded brake pipes that can result in decreased brake effectiveness. ODI will continue to gather information on subject vehicles outside the Salt Belt as well.
- Crank position sensor failure - stall
The office of defects investigation (odi) opened a preliminary evaluation (pe06-016) on may 4, 2006 based on eleven vehicle owner questionnaires (voqs) and early warning (ewr) data alleging sudden engine shutdown while driving as a result of crank position sensor failures in my 2001-2002 general motors c/k platform…
The office of defects investigation (odi) opened a preliminary evaluation (pe06-016) on may 4, 2006 based on eleven vehicle owner questionnaires (voqs) and early warning (ewr) data alleging sudden engine shutdown while driving as a result of crank position sensor failures in my 2001-2002 general motors c/k platform vehicles equipped with 8.1L engines.in response to an information request letter sent by odi, general motors (gm) provided owner complaint information, field reports and warranty claim data based on a population of 108,338 vehicles. The data was categorized by engine stalls while driving, engine stalls with an unknown driving condition, no start conditions and claims where it was indeterminate if an engine stall occurred while driving.general motor's response included 1,213 owner complaints and field reports of which 289 were categorized as engine stalls while driving allegedly caused by crank position sensor failures. General motors also submitted warranty claims from its regular warranty (5 years/50,000 miles) and from its extended warranty database. From the regular warranty database there were 3,140 claims of crank position sensor replacement of which 147 claims were from consumers alleging engine stall while driving.gm stated that 2,841 of the claims were indeterminate if an engine stall occurred while driving.from its extended warranty database, gm submitted 1,561 claims of crank position sensor failure that it also stated were indeterminate as to whether an engine stall occurred while driving.in total, gm reports 4,701 claims of crank position sensor failure combining regular warranty and extended warranty.similar to gm's statistical analysis, odi's analysis showed that the failure rate for warranty claims of engine stall while driving at three years in service IS low (less than 1%).however, further analysis determined that the my 2001 vehicle build period from may 2000 through october 2000 had significantly higher (more than four times) crank position failure rates in both consumer complaint data and warranty claim data than in the build period from november 2000 through july 2001.adding the claims of known engine stall while driving and claims where engine stall was indeterminate, the failure rate at three years in service for this population IS over 6%.AN engineering analysis (ea06-016) has been opened to further assess the frequency and potential safety consequences associated with the alleged defect in vehicles built from may 2000 through october 2000.
- Parking brake failure
Odi's review of complaint data received since the close of ea04-011 revealed no indication that the investigation should be re-opened.more details can be found in the federal register notice enclosed in the dp05-009 public file.odi reserves the right to reopen the investigation in the future should conditions warrant.
- Unwanted low-speed ABS activation
In a letter dated august 29, 2005, gm notified odi that it was recalling certain model year 1999 through 2002 c/k pickup trucks and sport utility vehicles to correct a problem with anti-lock brake system (ABS) wheel speed sensor corrosion that may result in unwanted ABS activation and extended stopping distances…
In a letter dated august 29, 2005, gm notified odi that it was recalling certain model year 1999 through 2002 c/k pickup trucks and sport utility vehicles to correct a problem with anti-lock brake system (ABS) wheel speed sensor corrosion that may result in unwanted ABS activation and extended stopping distances during low-speed braking (recall 05v-379).gm's recall covers approximately 804,000 vehicles currently registered in the following 14 salt-belt states:connecticut, illinois, indiana, massachusetts, maine, michigan, new hampshire, new jersey, new york, ohio, pennsylvania, rhode island, vermont, and west virginia.the recall procedure will involve removing the sensor, cleaning the mounting surface, applying a rust inhibitor (zinc-x) to the surface, and reinstalling the sensor.if necessary, the sensor will be replaced. The population and failure report data given in this resume are for the full region that has been considered by odi as the salt-belt.that includes delaware, iowa, maryland, minnesota, missouri, wisconsin and the district of columbia in addition to the 14 states included in 05v-379.the states covered by gm's recall have the highest incident rates for the subject condition, accounting for 91% of the incidents, but only 24% of subject vehicle sales in the united states.odi's analysis determined that 840 of the complaints, 244 of the crashes, and 16 of the injuries identified in this investigation occurred in those states.the resulting incident and crash rates are 96.2 and 28.0 per 100,000 vehicles respectively (note:rates are based on vehicle sales, not registered vehicles). The corresponding numbers in the excluded portions of the salt-belt are 399,000 vehicles, 81 incidents (20.3 per 100,000 vehicles), 3 crashes, and no injuries.the statistics in the remaining 30 states are 2,406,000 vehicles, 168 incidents (7.0 per 100,000 vehicles), 31 crashes, and one injury.gm and odi are continuing to monitor the problem experience in states that are not included in the recall.gm will provide odi with updated complaint, field report, and warranty data in november 2005.odi and gm will review that data and assess the appropriateness of the current scope of the recall at that time.
- Parking brake failure
In a letter dated april 20, 2005, gm notified nhtsa that it had decided that defects that relate to motor vehicle safety exist in certain model year (my) 1999-2002 c/k 1500 series (pbr parking brake system) and my 2001-2005 c/k 2500 and 3500 series (trw parking brake system) pickups with manual transmissions.according…
In a letter dated april 20, 2005, gm notified nhtsa that it had decided that defects that relate to motor vehicle safety exist in certain model year (my) 1999-2002 c/k 1500 series (pbr parking brake system) and my 2001-2005 c/k 2500 and 3500 series (trw parking brake system) pickups with manual transmissions.according to gm, some of these vehicles may have conditions that cause the friction linings to wear to an extent where the parking brake can become ineffective in immobilizing a parked vehicle.gm's action covers an estimated total of 142,585 vehicles.dealers will install a low-force spring clip retainer for vehicles equipped with the pbr parking brake system and install a redesigned parking brake cable assembly on vehicles equipped with the trw parking brake system. A total of 58 non-duplicative complaints were received by odi and gm concerning the approximately 59,000 my 1999-2002 c/k 1500 series pickup trucks with the pbr parking brake system.these included 22 alleged rollaway incidents, resulting in a rate of 38.5 rollaway incidents per 100,000 vehicles.odi IS aware of 24 complaints regarding the my 2001-2005 c/k 2500 and 3500 series manual transmission trucks recalled by gm, including 5 alleging rollaway incidents.though the conditions described in gm's letter are also present in the c/k trucks with automatic transmissions, the rollaway rate in those vehicles was similar to those observed in peer vehicles studied by odi in this investigation.this engineering analysis IS closed. For additional information, see the attached closing report.
- Tailgate cable breakage
General motors filed a defect notice 04v-129 on march 17, 2004, which outlines a program to replace the tailgate cables installed in affected model year 2000-2004 vehicles.refer to odi's closing report for ea04-005 for additional information.odi IS aware of reports of tailgate cable breakage occurring in model year…
General motors filed a defect notice 04v-129 on march 17, 2004, which outlines a program to replace the tailgate cables installed in affected model year 2000-2004 vehicles.refer to odi's closing report for ea04-005 for additional information.odi IS aware of reports of tailgate cable breakage occurring in model year 1999 and earlier vehicles.these vehicles were equipped with similar tailgate cables as addressed by 04v-129, but are not being addressed by campaign o4v-129.odi IS initiating a separate investigation to address these vehicles.the complaint-injury-fatality statistics summarized above pertain to model year 2000-2004 vehicles. The complaint-injury statistics for model year 1999 and earlier vehicles are summarized on the opening resume for that investigation.
- Parking brake failure
Odi opened pe03-057 to assess parking brake ineffectiveness in the subject vehicles.these vehicles are equipped with four wheel disc brakes that incorporate a single-shoe drum-in-hat parking brake independent of the service brakes.complaint and warranty data indicate that the parking brake linings tend to wear out…
Odi opened pe03-057 to assess parking brake ineffectiveness in the subject vehicles.these vehicles are equipped with four wheel disc brakes that incorporate a single-shoe drum-in-hat parking brake independent of the service brakes.complaint and warranty data indicate that the parking brake linings tend to wear out early in the life of the vehicle (at an average of 24 months in service), reducing the parking brake system's torque below that needed to immobilize the vehicle.gm has attributed this accelerated wear to foreign material intrusion and a failure of the brake shoe to properly self-center within its brake drum.effective with the start of my 2003 production, a newer reduced force hold-down clip was introduced to facilitate brake shoe disengagement from the drum surface.this part IS also available at the service level for the my 1999-2002 vehicles.gm has indicated that the paking brake IS intended to operate in conjunction with the transmission to immobilze parked vehicles, and that in many cases, accelerated parking brake lining wear IS caused by rough use, vehicle modifications, and driving with the parking engaged. Odi has upgraded the preliminary evaluation to an engineering analysis to gather further information concerning parking brake usage factors and the circumstances surrounding the seventeen reported vehicle crashes.
- Throttle sticking closed
This investigation involves the general motors corporation (gm)throttle body (tb) utilized in model year (my) 1999-2002 silverado, sierra, tahoe, suburban, avalanche and yukon (subject vehicle(s)) with 4.8L, 5.3L, and 6.0L engines. The tb valve may intermittently stick in a closed position.in such a situation, an…
This investigation involves the general motors corporation (gm)throttle body (tb) utilized in model year (my) 1999-2002 silverado, sierra, tahoe, suburban, avalanche and yukon (subject vehicle(s)) with 4.8L, 5.3L, and 6.0L engines. The tb valve may intermittently stick in a closed position.in such a situation, an operator may apply additional accelerator pedal force to increase engine speed.the application of additional accelerator pedal force, to open a stuck throttle valve, may open the throttle valve more than intended and, in turn, accelerate the engine and vehicle more than intended and reasonably expected by the driver.on august 1, 2002, the office of defects investigation (odi), of the national highway traffic safety administration (nhtsa), opened this engineering analysis.the investigation revealed that two factors may cause the defect: 1) tb manufacturing process problems; and 2) accumulation of deposits (a pcv system by-product) on or around the tb throttle valve and bore.odi concludes that the tb performs in a defective manner after analyzing gm?s data submissions, and test data collected by the vehicle research and test center (vrtc).fifty-nine crashes are alleged to have occurred as a result of gm?s tb defect.the majority of the crashes involve a single vehicle, engaging in a close quarter vehicle maneuver (or low speed), and causing only minor property damage.four out of the fifty-nine crashes involve injury, and those injuries were minor.although gm?s tb IS defective, based on the evidence gathered, odi has found that the accelerator pedal force required to open a stuck throttle valve IS negligible, and the throttle valve does not stick in the open position.therefore this engineering analysis (ea02-015) will be closed at this time.the closing of this investigation does not constitute a finding by nhtsa that a safety-related defect does not exist.for a detailed discussion of the tb component and testing, please see the attached report.
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 10114470This Preliminary Information communication provides information to the technician about vehicle that may have an OnStar system that has progression tones when pressing the blue or red button. Technician will need to call General Motors Technical Assistance Center with the scan tool data from the OnStar system.
- 10114431This Preliminary Information communication provides information to the technician about vehicles that may have an issue when using Bluetooth voice recognition with an iPhone. Technician should work with the customer to insure the phone contacts to not have any Emojis loaded to any contact.
- 10114408This Preliminary Information communication provides information to the technician about vehicles that are travelling from Canada to the United States. While in the United States they are unable to receive Turn-by-Turn directions. Due to the existing cellular provider not having roaming agreements in areas outside of Canada to support transmitting of the packet data required for Turn-By-Turn feature to operate. The customer has 3 options while traveling through the United Sates. First if the vehicle is equipped with a navigation radio they can request a "Destination Download" to the vehicle. Second if the customer uses the OnStar RemoteLink app they can send the directions to the vehicle. The third option would be to have the vehicle loaded with a "500 phone number" The customer will no longer be able to use their Hands Free Calling minutes when the new 500 phone number is loaded. If a customer chooses to restore Hands Free Calling in the future a new phone number will be assigned to the vehicle; previous phone numbers are not available.
- 10114343This Preliminary Information communication provides information to the technician the steps needed to diagnose and repair the vehicles that may have unwanted or phantom phone calls. Technician will need to determine what type of call the customer is having that is unwanted. The vehicle may receive an incoming call just like any other phone. Typically the customer will hear the phone ringing in the vehicle. This scenario also includes incoming Bluetooth calls. One type of unwanted call can be made if the key pad is faulty the OnStar system will try to make a blue button call for shorted voltage in the circuits. The OnStar module could have an internal fault and produce a "Phone Unavailable" audio message also it may have a Diagnostic Trouble Code U1500 or B1000. Refer to diagnostics for the Diagnostic Trouble Code making sure to follow any applicable Bulletins or Preliminary Information sheets. A "Ready" or "OnStar ready" audio message heard while driving. In some cases it has been found that the customer is inadvertently pressing the ?push to talk? button on the steering wheel controls. On rare occasions, other issues in the steering column or Steering Wheel Control system may induce this concern.
- 10114342This Preliminary Information communication provides information to the technician about vehicle that may have an OnStar system that has progression tones when pressing the blue or red button. Technician will need to call General Motors Technical Assistance Center with the scan tool data from the OnStar system.
- 10113843This warranty administration bulletin provides information on the Clarification of Use for Dealer Empowerment Labor Operations and Customer Enthusiasm
- 10113722This informational bulletin provides information on communication with OnStar module after Canadian cellular upgrade.
- 10113720This informational bulletin provides information on a GM of Canada OnStar cellular communication upgrade.
- 10113662This informational bulletin provides dealership personnel with information on flexible fuel vehicles (FFVs) and the usage of E85 fuel in GM vehicles.
- 10113654This informational bulletin provides information on a GM of Canada OnStar cellular communication upgrade.
- 10113406This Preliminary Information communication provides information to the technician about vehicles that may have slack in one of the tailgate cables. Technician should not replace any parts for this concern. Please communicate to the customer this condition is a normal operating characteristic of their vehicle.
- 10113364This Preliminary Information communication advises the technician that the Hydro-Boost is not serviceable and will need to be replaced if the brake pedal moves or applies on its own at a full turn.
- 10112900This Preliminary Information communication provides information to the technician about vehicles that will not move in forward or reverse. Technician may find Diagnostic Trouble Code P0877 or P2723 set. Technician will need to inspect the valve body separator plate orifices for debris.
- 10112697This Preliminary Information communication provides information to the technician about vehicles that have a Service Engine Soon Malfunction Indicator Lamp on, engine misfire, and/or engine noise. Technician may find Diagnostic Trouble Codes P0300-P0308. If published Service Information diagnostics does not isolate the cause of this concern technician should check for a worn camshaft lobe and/or lifter roller, a sticking valve, valve leakage, a broken valve spring, and a collapsed active fuel management lifter.
- 10112681This Preliminary Information communication provides information to the technician about vehicles that may have a planetary gear whine noise in first and second gear. Technician should compare the noise to a like vehicle. Technician will need to check the build date of the transmission, if it was built after 09/01/2003 and it is determined that a vehicle has an abnormal amount of noise, perform the rear unit end play check. Technician will replace the output planetary gear set if end play is out of specification. The transmission assembly will need to be replaced if the end play is with in specification.
- 10112655This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed for the vehicle in question and its applications. Technician should not use the information that is provided by the antilock braking system tire size selection.
- 10112546This Preliminary Information communication advises the technician that the Hydro-Boost is not serviceable and will need to be replaced if the brake pedal moves or applies on its own at a full turn.
- 10112523This Preliminary Information communication provides information to the technician about vehicles that have slip in forward ranges immediately after replacing the input housing. Technician will inspect the 3-4 clutches and the forward clutch oil feed passages for leakage between circuits. Technician should apply regulated compressed air to the 3-4 clutch feed hole and the forward clutch feed hole one at a time with the input housing. Technician will need to replace the input housing if there is an air leak 3-4 clutches.
- 10112401This Preliminary Information communication provides information to the technician about vehicles that have not engagement into drive, delayed, no engagement into reverse, and or a range inhibit. Technician may find Diagnostic Trouble Codes P0701, P0731, P0732, P0733, P0734, P0736, P0751, P0756, P0761, P0776, P0843, P0848, P0873, P0877, P0894 or P2723. Technician should follow published Service Information diagnostics for Diagnostic Trouble Code P0701 first. Technician will also ensure the fluid level is at the top of the hot band when the transmission fluid temperature is 175 Fahrenheit. Diagnostic Trouble Codes P0701, P0731, P0732, P0733, P0734, P0736, P0751, P0756, P0761, P0776, P0843, P0848, P0873, P0877, P0894 or P2723 can set by the following fluid service/filter change, transmission service involving removing the pan, low fluid level caused by leaks, or after long periods of storage. If the fluid level has been properly checked using the HOT check procedure listed in Service Information document 2408059 and any of the Diagnostic Trouble Codes reset during a cold start inspect the internal suction filter for possible cracks. If no other concerns are found inspect for a stuck lube regulator valve in the pump cover due to debris.
- 10112382This Preliminary Information communication provides information to the technician about the percentage of UV protection or tint offered by the windshield or side glass. Technician should be advised Windshield reduces UV rays down to 4% or less. Front side door glass reduces UV rays down to 35% or less. Windshields are SOLAR glass with a light transmittance of >/=70%. Front door glass are Solar glass with a light transmission of >/=70%. Rear door glass, quarter windows and back windows can use either Solar glass (>/=70%) or Privacy glass, which has a light transmittance of 20%.
- 10112299This informational bulletin provides information on Part Restriction and Ordering Process Information for OnStar Vehicle Communication Interface Modules (VCIM) (GMNA Only)
- 10108599This technical bulletin provides a procedure to lube the rear leaf springs on vehicles with the condition of a squeak noise originating from the rear of the vehicle.
- 10056354Gmc/chevrolet: engines, with egr system, has leakage from egr cooler engine coolant into the combustion chamber. Model 2002-15 silverado, sierra, 2004-09 kodiak c4500-c5500, topkick c4500-c5500, 2006-15 express, savana.
- 10054261Chevrolet/gmc/cadillac: anytime hydraulic brake pipes assembly need replacing, pre-formed and pre-flared brake pipes are available, except rear axle crossover pipe. Model 1999-2007 silverado, sierra, 2000-2006 escalade models, avalanche, suburban, tahoe, yukon models. Updated 7/18/14. Updated 12/9/14.
- 10042986General motors: information provided by bulletin for all 2012 and prior general motor trucks and passenger vehicles regarding the adjustable comfort and custom upholstery of the driver and the passenger head restraint.
- 10038344Gm: the front or rear door may not open from the inside or outside handle, the door will not unlock with any method. The probably cause an incorrect installation of a handle component. Updated on 7/26/2013. All 2014 and prior gm passenger cars and trucks.
- 10038295Gm: information on fixing multiple situations right the first time.
- 10038294Gm: there are seat belt problems: difficulty latching and unlatching buckle. Buckle release button IS sticking. Seat belt warning light illuminated. Likely caused by sticky beverages that are spilled into the buckle assembly. Updated 4/3/12.
- 10037933Gm: the service engine soon light IS on, there IS also a misfire or engine noise. There are multiple possible causes.
- 10036545Buick/cadillac/chevrolet/gmc/oldsmobile and hummer: information on pitman arm shaft seal service kit. Do not replace entire steering gear for pitman seal leak. Technicians have been replacing entire steering gears due to not being able to service just leaking pitman shaft seal. Updated 5/9/11.
- 10027804General motors corp: special coverage adjustment; analog onstar deactivation. Updated 2/17/09.
- 10026804GMC: fluid leak from transmission oil cooler lines due to corrosion. All 2000-2006 light duty trucks equipped with the light duty automatic transmission.
- 10026704GMC: fuel gauge fluctuation in park or neutral, causing the low fuel light to illuminate.
- 10026586Buick\cadillac\chevrolet\gmc\hummer\oldsmobile\pontiac\saab\saturn service campaign: see document search button for owner letter. Special coverage adjustment-analog onstar deactivation. Fcc ruled in 2002 wireless carriers would no longer re required to support analog wireless network starting in 2008. Csc letter was received. Updated 12/1/08.
- 10025462Diagnostic information on MN8, MT1 ses/mil illuminated, dtc p0757, harsh shift, delayed 2-3 shift, 2-3 shift flare, no third gear, slips in third gear or reverse.
- 10025148Clunking noise under hood and can be felt in steering wheel and/or steering column (replace upper intermediate steering shaft [i-shaft] assembly).
- 10024345Eaton locking differential chatter shudder noise on turns, equipped with a locking rear differential rpo G80. Updated 7/17/2008.
- 10024344Possible engine oil leak due to pcv freeze-up, equipped with the 4.8, 5.3, 6.0, and 6.2 V-8 engines.
- 10024154Chevrolet\gmc service campaign: see document search button for owner letter. Special coverage adjustment - engine glow plug on certain vehicles with 6.6L diesel V8 (rpo LB7 - vin 1) engine & california emissions (yf5/ne1) or clean fuel emissions (vcl). Csc was received.
- 10023751Engine surge or stall at stop and/or dtc p0742 possible tcc applied. Equipped with allison lct1000 transmission rpo M74 or MW7. Updated 4/22/13.
Every GMC Sierra model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.