2002 GMC Sierra 2500
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
Have the VIN?
Vehicles › GMC › Sierra 2500 › 2002
These records cover every 2002 GMC Sierra 2500. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
4 recalls name the 2002 GMC Sierra 2500. Newest first.
Certain federal-mogul national and carquest aftermarket hub assemblies, p/n 515058, sold for use on 2001-2006 general motors 1500 and 2500 4WD trucks. on the subject hub assemblies, the ABS sensor cord departs from the hub assembly at a 90 degree angle. as a result, there IS a fit issue with the brake rotor dust shield interfering with the ABS sensor…
Risk and remedy
Risk
If stopping distance IS limited, a vehicle crash could occur.
Remedy
Federal-mogul will notify its owners and will either credit the customers account or replace the unit. the recall IS expected to begin during june 2006. owners can contact federal-mogul customer service at 1-800-563-8507 ext 3530.
Certain replacement fuel filters, fram brand name p/n g3727, with date codes x52911 through x60801 sequentially or x600141 and a mexico country or origin marking on the fuel filter housing manufactured from october 18, 2005, through march 21, 2006, sold for use on the vehicles listed above and on certain school buses. (to see the school bus engine sizes…
Risk and remedy
Risk
This condition may cause an inadequate seal at the connection, potentially leading to a fuel leak. In the presence of an ignition source, a fire could occur.
Remedy
Honeywell will notify owners and replace the fuel filters free of charge. the recall began on october 18, 2006. owners may contact fram customer service at 1-800-890-2075 (option 1).
Certain fabtech aftermarket replacement pitman arms, p/nos. Fts71000 and fts71001, installed for use on certain 2001-2006 gm c/k 2500 pick up trucks and sport utility vehicles. the pin located inside the pitman arm can shear off due to a reverse bending fatigue condition, resulting in a total loss of steering control.
Risk and remedy
Risk
Loss of steering control could lead to a vehicle crash with potential injury or death.
Remedy
Fabtech will notify owners and replace the pitman and idler arms free of charge. the recall IS expected to begin during february 2006. owners may contact fabtech at 909-597-7800.
Vehicle description: certain pickup trucks equipped with 6.6L diesel engines fail to comply with requirements of fmvss no. 105, "hydraulic and electric brake systems." these vehicles have a brake system warning light in the instrument cluster that may not illuminate when the brake fluid IS low. In addition, when the brake fluid IS low, the vehicle may…
Risk and remedy
Risk
These conditions could result in reduced braking capability, which could lead to a crash.
Remedy
Dealers will change the location of a wire connection in the underhood bussed electrical center. owner notification began july 9, 2001. owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact chevrolet at 1-800-222-1020 or GMC at 1-800-462-8782.
Owner complaints
134 complaints10 involved a crash1 involved a fire8 injuries1 deaths
What owners report most
Latest complaints
- Air bags
We were in a roll over accident going under 30mph. I was a passenger in the back seat. When I woke up I saw that the driver was hanging out the door window. The air bags did not deploy. The driver who was also the owner of the truck died of multiple blunt forces. The insurance company had the truck towed to COPART in Las Vegas.
- Air bags · Seat belts
While traveling on the highway we hit black ice and ultimately ended up with a front impact which turned into a 2 time vehicle rollover. Both front seat belts and buckled during the rollover and did not lock and neither of the airbags in front when off at any point during the collision
- Fuel/propulsion system · Power train · Service brakes
I purchase this truck 2/03/17 and have used it until 2 weeks age when the brake lines broke in my driveway, I am having the lines replaced with stainless lines at a cost of about $1200 ( I am not sure of the total cost because it also needs a antilock braking pump which was badly corroded) the fuel…
I purchase this truck 2/03/17 and have used it until 2 weeks age when the brake lines broke in my driveway, I am having the lines replaced with stainless lines at a cost of about $1200 ( I am not sure of the total cost because it also needs a antilock braking pump which was badly corroded) the fuel lings are also rusted and need to be replaced and also the transmission cooling lines need to be replaced at a cost to be determined later. I have a 1953 chevy pickup that still has good brake lines and the frame IS in better shape than the newer ones, if gm looked to the past at the materials & methods they might build a better product rather than the garbage they produce now! I am glad I didn't pay $30-$60,000 for this truck.
- Fuel/propulsion system · Suspension
The tubular frame that supports both the gas tank and rear passenger side shock absorber extremely rusts out causing the frame to eventually disconnect from itself and allow the gas tank to drop and/or the shock to disconnect from the axle, both in which may cause a fatal accident.
- Steering
While driving of a city street, at a slow rate (10-15mph) and taking a slow, approximately 90 degree left turn, I heard a loud "popping/breaking sound". While making the turn, I initially had turning capabilities until I heard the "pop" sound. Upon hearing the sound, I no longer had the ability to…
While driving of a city street, at a slow rate (10-15mph) and taking a slow, approximately 90 degree left turn, I heard a loud "popping/breaking sound". While making the turn, I initially had turning capabilities until I heard the "pop" sound. Upon hearing the sound, I no longer had the ability to turn the wheels to either direction. Upon stopping and turning off the truck, I found the pitman arm(connected to steering box and steering bar) was detached from the steering bar but still attached to steering box. The bolt of the pitman arm had broken off cleanly from the steering bar, rendering my steering capabilities ineffectual. Attached IS a picture of the pitman arm sheered bolt. I would like to file a complaint that this defective piece of material could have cost damage to life, property and potentially death of myself or others on the road. I would like some form of restitution on part of the manufacture. The total cost of the repair was approximately $225 usd. I can provide the bill for towing, mechanical repairs and cost of replacement part. *tr
- Service brakes
Anti-lock brakes engage on dry pavement just prior to coming to a complete stop.
- Service brakes
I have owned many gm trucks, and never had one with so many rusted out brake lines. Why can't they make them with stainless steel lines. They should have a recall for this. What happens when front and back lines go at the same time, I will tell you, no brakes ! This IS the worst one with the rust…
I have owned many gm trucks, and never had one with so many rusted out brake lines. Why can't they make them with stainless steel lines. They should have a recall for this. What happens when front and back lines go at the same time, I will tell you, no brakes ! This IS the worst one with the rust that I have had. 3 lines rust out on the GMC 2500 HD (2002) with more to come, I have 25,000 miles on this truck. The first line went about 15,000 miles. Also I only got about 5,000 miles on those firestone tires, cheap tires come with this truck. I have also noticed the frame IS rusting, had to have the cable replaced that shifts the truck into gear, it rusted out. I go to the car wash and always wash the underside of the truck to get all the dirt and salt off every chance I get. When I got the GMC I was told by the GMC garage not to have the truck undercoated because it would void the warranty on it. I also had to have the cables replaced on the tail gate due to rust. Very sad about this GMC truck. Everything IS rusting. I should have a lot of miles left on this truck, if it doesn't rust itself to death or get me killed because of rusted out brake lines !
- Service brakes
Rear steel brake line failure while in parking lot, complete loss of braking ability
- Service brakes
TL* the contact owns a 2002 GMC sierra 2500 HD. The contact stated that while driving 5 mph, when the brake pedal was depressed and the brakes failed. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was 60,000.
- Fuel/propulsion system · Service brakes
Driving into driveway applied brakes , pedal went right to the floor no warning light or any indication of a problem got out of truck and found fluid dripping off frame by fuel tank. ruptured line above tank on frame, other brake lines also look corroded. after some research I found this to be a…
Driving into driveway applied brakes , pedal went right to the floor no warning light or any indication of a problem got out of truck and found fluid dripping off frame by fuel tank. ruptured line above tank on frame, other brake lines also look corroded. after some research I found this to be a common problem on gm trucks . Owners need to be made aware of this problem before someone IS seriously hurt. I believe gm should be forced to repair the defective lines. *tr
- Service brakes
Driving down rural road at 55mph, a deer jumps into my path. I quickly brake, ABS activates and pedal drops to near floor. Truck does stop, but braking much more different than normal. Deer moves on and I start moving again. Next stop sign I notice that brake pedal drops to floor, still braking…
Driving down rural road at 55mph, a deer jumps into my path. I quickly brake, ABS activates and pedal drops to near floor. Truck does stop, but braking much more different than normal. Deer moves on and I start moving again. Next stop sign I notice that brake pedal drops to floor, still braking, but much more difficult to brake. I made it home and noticed my brake line directly under the driver position was spraying fluid now. *tr
- Service brakes
Pulling out of my driveway onto the street. Applied the brakes when reaching the end of the driveway and brake pedal when completely to the floor. Was able to stop, being that I was only going around 2 mph at the time. When I got out of the truck, I saw a large amount of brake fluid on the driveway from a burst brake line. *tr
- Air bags
Air bag sensor went out. 4TH alternator was replaced on 6 jan 14; three others were replaced between 9 mar2012 and 6 jan 14. resistor for air conditioning replaced on 9 jul 13. front hubs failed twice requiring their replacement within six months. front brake pads replaced twice in 16 months…
Air bag sensor went out. 4TH alternator was replaced on 6 jan 14; three others were replaced between 9 mar2012 and 6 jan 14. resistor for air conditioning replaced on 9 jul 13. front hubs failed twice requiring their replacement within six months. front brake pads replaced twice in 16 months and 10,718 miles. check engine light has stayed on continuously during this time, even after reset on four occasions. *tr
- Service brakes
Brakes failed while driving down road. all brake lines are severely rusted. IS their a galvanic reaction between lines and truck that IS causing this? have never had brake lines rust as badly on other vehicles that were older than this one. *tr
- Service brakes
I had been driving for 15-20 miles both on and off the highway and the vehicle stopped fine. I was traveling at about 60 mph and was coming up on highway traffic that was at a standstill . I stepped on the brake peddle and it went strait to the floor, absolutely no brakes at all and no even a…
I had been driving for 15-20 miles both on and off the highway and the vehicle stopped fine. I was traveling at about 60 mph and was coming up on highway traffic that was at a standstill . I stepped on the brake peddle and it went strait to the floor, absolutely no brakes at all and no even a hint this was about to happen. I was able to swerve out of the way, narrowly missing the vehicle in front of me, and used the transmission and e brake to get the vehicle stopped on a grassy shoulder. had a vehicle been next to me or a less experienced driver been behind the wheel, it may have been a much worse outcome . I know at least 10 people who own similar vehicles and everyone has had a brake line failure at some point. gm needs to step up and cover this before someone else get hurt or killed! *tr
- Service brakes
2002 GMC sierra 2500hd 4X4 4DR complete brake failure when moving vehicle at hunt camp.brake pedal went completely to floor.rusted brake lines blew under drivers door location.local mechanic replaced lines from master cyl. To ABS device. if this had happened the day before,with truck loaded…
2002 GMC sierra 2500hd 4X4 4DR complete brake failure when moving vehicle at hunt camp.brake pedal went completely to floor.rusted brake lines blew under drivers door location.local mechanic replaced lines from master cyl. To ABS device. if this had happened the day before,with truck loaded with supplies ,eqpt.,and towing an atv on a trailer,no way could I have stopped that vehicle! I still need to replace all remaining rusted lines going to wheels. *tr
- Service brakes
Backing my truck down a boat launch to put a pwc in. as I applied the brake at the bottom of the ramp, the pedal went to the floor, losing all brakes. since I was close to the water, by the time I got it into forward, it was already over the edge of the ramp into the water. submerged up to the bottom of the roof. a total loss. *tr
- Service brakes
Steel brake line ruptured with no warning under the drivers side floor panel. It was the line from the master cylinder to the anti-lock brake actuator. read dozens of online postings about this being a huge problem and was encouraged to report it. safely stopping the truck (empty) was very hard and I couldn't imaging what would have happened if I had been pulling a trailer, which IS very common on this truck. *tr
- Service brakes
Approaching a stop light of a 55 mph road and applied the brakes. the truck failed to stop. I went through the red light but did not hit any other cars. *js
- Service brakes
Brakes went out no warning, after looking on drivers side seat under truck where fluid was running out saw where brake line was rusted and it busted. So I took several pictures and called GMC, they in turn towed my truck to auffenberg of carbondale, illinois at no charge. At this time I started…
Brakes went out no warning, after looking on drivers side seat under truck where fluid was running out saw where brake line was rusted and it busted. So I took several pictures and called GMC, they in turn towed my truck to auffenberg of carbondale, illinois at no charge. At this time I started researching the rusted brake problem and found where alan adler (manager product safety communications) for gm said on (abc news rusted brake lines) where they were offering a (kit) to have the rusted brake lines repaired for a cost to us of $500.00. So now today 06/05/2014 my truck IS done at a cost of $1188.05 to me for the dealer knows nothing of this. I have tried to contact alan adler through gm and no one knows who he IS, I have sent many complaints and talked with many people and no one seems to know what I am talking about. My ref.# [xxx] with the complaint dept. So if this man can say on the news that they have this kit and that all the dealers were told about it how can they lie and charge the people what they want. Thank you information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(B)(6). *tr
- Service brakes
Was leaving my drive way and went to put on brakes and they made a hissing sound and peddle went all the way to the floor and brake fluid started pouring out, so pushed emergency brake and nothing happened there was no brakes. with help got truck back in drive way and got under truck where fluid…
Was leaving my drive way and went to put on brakes and they made a hissing sound and peddle went all the way to the floor and brake fluid started pouring out, so pushed emergency brake and nothing happened there was no brakes. with help got truck back in drive way and got under truck where fluid was leaking and the brake lines were all rusted into. Thank god I didn't make it down the road before they went out and hit or killed someone. *tr
- Service brakes
Rear brake line rusted out over fuel tank where line runs on top of frame rail. All brake lines rusted. Also fuel lines rusted. Can or will fail at anytime. May cause an accident. No brake failure light!!!! *tr
- Engine
Three broken manifold bolts. From what I hear this IS a common occurrence. The broken one close to firewall, will have to pull engine to fix. There should be a recall on these manifold bolts. *tr
- Power train
The transmission came out of reverse, and would not return. No reverse or drive at all. *Tr
- Service brakes
The vehicle was parked on a 35-40 degree sloped driveway. Got in, stepped on brake,started vehicle, released emergency brake, shift into reverse, and brake pedal went to the floor, with truck rolling backwards. Wheel was turned, and truck hit a side of retaining wall. It did not roll back…
The vehicle was parked on a 35-40 degree sloped driveway. Got in, stepped on brake,started vehicle, released emergency brake, shift into reverse, and brake pedal went to the floor, with truck rolling backwards. Wheel was turned, and truck hit a side of retaining wall. It did not roll back excessively fast, but it could not stop in time to avoid hitting the wall. found badly corroded brake lines. One had ruptured right behind the driver's front wheel fender well. *tr
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Trailer hitch receiver failure
Complaint reports allege poor weld quality and/or bending of the subject vehicle original equipment trailer hitch receiver.the agency's investigation included analysis of manufacturer and agency incident reports, review of police reports, analysis of the agency's fatal analysis reporting system, a vehicle owner…
Complaint reports allege poor weld quality and/or bending of the subject vehicle original equipment trailer hitch receiver.the agency's investigation included analysis of manufacturer and agency incident reports, review of police reports, analysis of the agency's fatal analysis reporting system, a vehicle owner survey, inspection of tow vehicles/hitches and analysis of failed parts.incidents of weld failure were rare and associated with very low-speed driving (turning, backing and sudden stopping).incidents of bending were associated with improper trailer hitch adjustment or overloading. A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.accordingly, this investigation IS closed.the closing of this investigation does not constitute a finding by nhtsa that a safety-related defect does not exist.the agency will monitor this issue and reserves the right to take further action if warranted by the circumstances.see document search file for addition information.
- Trailer hitch receiver failure
Gm provided additional data regarding allegations of failure of the trailer hitch.odi reviewed that as well as other data provided by peer manufacturers.based on our review, odi finds the need to further investigate this issue.this preliminary evaluation IS upgraded to an engineering analysis (ea07-013) for further assessment and study of this issue.
- Hydraulic pump shaft failures
The preliminary evaulation IS being upgraded.during the ea odi will limitits investigation to only those vehicles equipped with a hydro-boost system, which provides power assist to the braking and steering sytems.vaccuum brake booster vehicles are excluded.odi hasexpanded the scope of the ea to include model years2003…
The preliminary evaulation IS being upgraded.during the ea odi will limitits investigation to only those vehicles equipped with a hydro-boost system, which provides power assist to the braking and steering sytems.vaccuum brake booster vehicles are excluded.odi hasexpanded the scope of the ea to include model years2003 and 2004, asduring the pe, odi learned that the hydroboast pumps were modified in febraury 2004.therefore,odi has expanded the scope to include the additional model years.odi's IS concerned because thisisa sudden failure that affects two critical systems of the vehicle, brakes and steering, at the same time.the ability of the operator to handle the dual failures IS a concern. Further, these vehicles tend to be work vehicles, with some over 10,000 pounds gvwr and many equipped to pull large trailers.dual failures of heavily loaded vehicles and vehicles pulling trailers further increases the safety risk.odi plans to conduct testing to quantify the braking and steering performance degradation and the impact on safe vehicle control, when a hydroboast pump fails.
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.
- 11010544This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.
- 11006621Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected modules (with some exceptions). The updating of modules is completed in parallel instead of the technician needing to update one module at a time. This allows a more streamlined approach for dealers and customers.
- 11006421GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the dealers to be more careful not to damage the transmissions during removal and to package the core properly for return.
- 11004761This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up.
- 11004557This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim.
- 11002312This service bulletin provides information for dealers/technicians on Service Programming System (SPS) Error Codes E4398, E4399, E4401, E4403, M4404, M4413, M6954, M6955, E4414, E4423, E4491, E4492, or E6961 and resolution information.
- 10252735This bulletin provides information for electrical ground repairs using new General Motors replacement fasteners with conductive finish.
- 10252163XM Audio Traffic And Travel Link Availability And Operation.
- 10251890This technical bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up.
- 10251887This bulletin advises the technician of possible location of an internal coolant leak from a specific cylinder head and location.
- 10250775This service bulletin provides service information to technicians on guidelines to replace Oil Cooler, Oil Cooler Lines and Oil Tank if the engine was replaced where large amounts of debris has flowed throughout the oiling system.
- 1025004605500 ignition distributor system corrosion inspect / replace
- 10250012Duramax Diesel Glow Plugs Difficult to Install Due to Carbon Buildup - New Glow Plug Bore Reamer Available
- 10249980This Preliminary Information communication provides information to the technician about vibration complaints that are one of the most challenging complaints to accurately diagnose and repair. Technician will need to use Pico Oscilloscope Diagnostic Kit to effectively diagnosis vehicles. Technician should drive the vehicle will using the Pico Oscilloscope to record data. After the data is recorded it should be reviewed to determine the root cause of the concern. If a repair attempt made the concern better but not eliminated or had no affect at all, and are requesting assistance from General Motors Technical Assistance Center record another Pico file and save it to the computer. After the new Pico Oscilloscope data has been saved email the data to General Motors Technical Assistance Center in the subject line include ?Vibration? ?Business Associate Code? and the last 8 of the Vehicle Identification Number.
- 10249590This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim.
- 10249579This PI bulletin advises the technician on the proper way to install the pistons in an engine.
- 10249011This informational bulletin provides information for dealers/technicians on Headlamp, Tail Lamp, License Lamp or Fog/Driving Lamp Damage.
- 10248444Vehicle Recalls
- 10247780This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature.
- 10247681Information On Requests To Add OnStar Bluetooth Option.
- 10247552This service bulletin provides information on Concerns or Questions Regarding Installation of Dealer Installed Accessories.
- 10246952Programming And Activation Of Replacement OnStar Modules.
- 10246951Programming And Activation Of Replacement OnStar Modules.
- 10246647Pre-Formed and Pre-Flared Hydraulic Brake Pipe Kits Now Available for Service
- 10246631Expanded Availability for Remanufacture and Return (R&R) Electronic Control Modules
- 10246499Duramax Diesel Glow Plugs Difficult to Install Due to Carbon Buildup - New Glow Plug Bore Reamer Available
- 10245951Canadian Customers Unable To Place Calls And Turn By Turn Inoperative In The United States.
- 10245950Canadian Customers Unable To Place Calls In The United States
- 10244274This service bulletin provides information about the Hunter wheel Road Force balancers that should be utilized for all repairs requiring balance and Road Force measurement.
- 10244201This service bulletin provides information for dealers on how to submit a product information report (PIR) (Canada Only).
- 10242843The service bulletin advises the tech of a normal transmission shift condition and the delay in throttle response when the throttle plate is opened rapidly and advises the customer that it is normal for the delay.
- 10242262This service bulletin provides graphics, information and guidelines for engine component wear to assist service personnel as a guideline to perform necessary engine repairs and prevent unnecessary engine replacement.
- 10242252This technical bulletin provides information and a solution to a condition of Brake Pedal Moves or Self Applies at Full Turns.
- 10240793This Preliminary Information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get record a sound clip or take a video of the noise for assessment by engineering. Technician will need to call General Motors Technical Assistance Center for further assistance.
- 10240344This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.
- 10236164This Preliminary information communicates information that will need to be provided to TAC to aid in diagnosing if a vehicle comes in with misfire and DTC Codes P0300 - P0308 and/or P050D
- 10235802This diagnostic tip bulletin provides additional information on how to diagnose a possible valve, lifter or camshaft issue.
- 10235799This service bulletin provides information about the Hunter wheel Road Force balancers that should be utilized for all repairs requiring balance and Road Force measurement.
- 10235713This bulletin provides information on Warranty Administration Required Operating Procedures - 8 Points (U.S. Only).
- 10234141This diagnostic tip bulletin provides additional information on how to diagnose a possible valve, lifter or camshaft issue.
Every GMC Sierra 2500 model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.