2002 GMC Sierra 3500
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › GMC › Sierra 3500 › 2002
These records cover every 2002 GMC Sierra 3500. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
3 recalls name the 2002 GMC Sierra 3500. Newest first.
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).
On certain vans equipped with sure-lok wheelchair securement systems, the sprocket teeth of the retractor assembly IS out of alignment.
Risk and remedy
Risk
In the event of a vehicle crash, the wheelchair may not be adequately secured possibly resulting in injuries to a wheelchair occupant.
Remedy
Dealers will inspect and replace the wheelchair securement retractors as necessary. sure-lok will handle the repairs for this campaign. owners should contact sure-lock at 1-908-231-1804 or mobilityworks at 1-800-769-8267.
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
20 complaints3 involved a crash1 involved a fire1 injuries
What owners report most
Latest complaints
- Engine
TL* the contact owns a 2002 GMC sierra 3500. While operating the vehicle, the odor of fuel was noticeable inside the cabin. Upon inspection, the contact discovered fuel had leaked from the vehicle onto the ground. The vehicle was taken to an independent mechanic who diagnosed that the fuel…
TL* the contact owns a 2002 GMC sierra 3500. While operating the vehicle, the odor of fuel was noticeable inside the cabin. Upon inspection, the contact discovered fuel had leaked from the vehicle onto the ground. The vehicle was taken to an independent mechanic who diagnosed that the fuel injectors needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The vin was not available. The failure mileage was 120,000.
- Fuel/propulsion system · Service brakes · Unknown or other
This truck has the same problems as the 2007 model. the ignition switch, parking brake, and fuel lines all have issues as similarly described for the 2007 model. the fuel lines actually broke through causing a leak of the diesel fuel. this happened after the vehicle was driven a short distance of 15 miles.
- Fuel/propulsion system
While driving down a very busy street, the engine died. I lost all my power steering and brake. I was very lucky that I was not on a very busy highway. I had it towed to hedrick's chevrolet in clovis ca. it took 2 days for them to check it out. they said when they went to bring it in to the…
While driving down a very busy street, the engine died. I lost all my power steering and brake. I was very lucky that I was not on a very busy highway. I had it towed to hedrick's chevrolet in clovis ca. it took 2 days for them to check it out. they said when they went to bring it in to the shop it started up and they could not find anything wrong with it. I picked the truck up and the next day it did the same thing again. I called the dealer and they told me to press the pump on the top of the filter housing until I could no longer press it. I did that and it started up. be came very obvious that they were aware that the fuel filter housing was causing the injection system to lose suction I took it back to the dealer and they replaced the fuel filter housing. I have since found out that this failure IS a common failure. evidently there IS an o ring in the housing and it fails and based on fact that their service person was able to tell me how to start the truck, they new of these failures and never told owners about this. ...Updated 09/22/15 *bf updated 12/9/2015 *js
- Fuel system, diesel · Service brakes · Suspension
Slowing down to a red traffic light and brake pedal went to the floor. Tried to pump brake pedal to get more pressure but did not work. Drove off onto shoulder and got it slowed down . Drive very slow with hazard lights on to get it back to my house. I was only about a mile away. Got home and…
Slowing down to a red traffic light and brake pedal went to the floor. Tried to pump brake pedal to get more pressure but did not work. Drove off onto shoulder and got it slowed down . Drive very slow with hazard lights on to get it back to my house. I was only about a mile away. Got home and looked underneath to find brake fluid all over left rear wheels, fuel tank, left rear shock and drive axle. Continued to look at all brake lines and all of them were corroded bad. Getting prices on having all brake lines replaced. *tr
- Fuel/propulsion system · Fuel system, diesel · Service brakes · Service brakes, hydraulic · Vehicle speed control
I first noticed that the anti-lock brakes were activating at slow speeds ( 5-10 mph ) under dry road conditions. This was prior to brake line incident on 4-14-2012 but I am not sure of exact date. I researched the anti-lock brakes and found nhtsa ID campaign #05v379000 action # pe05020 but this did…
I first noticed that the anti-lock brakes were activating at slow speeds ( 5-10 mph ) under dry road conditions. This was prior to brake line incident on 4-14-2012 but I am not sure of exact date. I researched the anti-lock brakes and found nhtsa ID campaign #05v379000 action # pe05020 but this did not include my home state of kentucky. However, I have been working in ohio since the purchase of said vehicle 10-17-2001 to current date 2-11-2013. on 4-14-2012 I was preparing to take my boat to fuel it . While checking the trailer lights I stepped on the brake pedal and it went straight to the floor. I found that the brake line to the rear wheels had burst in half and was severely corroded. Upon closer inspection I found that all the brake lines showed signs of severe corroision. On 2-8-2013 I discovered that diesel fuel was leaking near the fuel tank and fuel cooler. It was found to be a corroded return fuel line between the cooler and the fuel tank .again upon closer inspection all fuel lines show moderate to severe corroision. *tr
- Service brakes
This morning I noticed the brake pedal traveling down further than normal and little to no stopping power. once arriving at work I tried to pump the brake pedal and it kept going to the floor. upon looking under the truck I discovered a puddle of brake fluid. after further inspection I found one…
This morning I noticed the brake pedal traveling down further than normal and little to no stopping power. once arriving at work I tried to pump the brake pedal and it kept going to the floor. upon looking under the truck I discovered a puddle of brake fluid. after further inspection I found one of brake lines had rusted through and blown out in front of the ABS module. the general condition of all the brake lines in this area IS very rusty. I will likely have to replace all the brake lines due to this. *tr
- Fuel system, gasoline
TL* the contact owns a 2002 GMC sierra 3500. While driving approximately 65 mph, the vehicle began to smoke and lose power abnormally. The vehicle was taken to an authorized dealer where the fuel filter was replaced. The failure recurred in less than one year. The vehicle was taken back to the…
TL* the contact owns a 2002 GMC sierra 3500. While driving approximately 65 mph, the vehicle began to smoke and lose power abnormally. The vehicle was taken to an authorized dealer where the fuel filter was replaced. The failure recurred in less than one year. The vehicle was taken back to the dealer and the contact was advised that there were three defective fuel injectors that would need replacing. The contact stated that the vehicle was previously repaired under nhtsa campaign ID number: 06e043000 (fuel system, gasoline) yet the repair did not remedy the failure. The vin was unavailable. The approximate failure mileage was 80,000 and the current mileage was 82,828.
- Service brakes, hydraulic
Tl*the contact owns a 2002 GMC sierra 3500. while driving 15 mph, the antilock brake system began to activate in normal weather conditions. as a result, the brakes began to tremble. the vehicle was taken to the dealer, but they were unable to determine the cause of the failure. the vehicle was…
Tl*the contact owns a 2002 GMC sierra 3500. while driving 15 mph, the antilock brake system began to activate in normal weather conditions. as a result, the brakes began to tremble. the vehicle was taken to the dealer, but they were unable to determine the cause of the failure. the vehicle was taken to a local repair shop and a technician stated that there was corrosion of the wheel speed sensor, which caused the ABS to activate. no repairs have been made. the manufacturer stated that the vin was not included in the recall and no reimbursement would be provided. the nhtsa campaign ID number was unknown. the failure mileage was 49,100 and current mileage was 50,289.
- Service brakes, hydraulic
My ABS brakes prevent my truck from stopping at slow speeds. *tr
- Air bags › Frontal
Tl*the contact owns a 2002 GMC 3500. while driving 35 mph, the contact swerved to avoid a deer and struck a concrete wall. none of the air bags in the vehicle deployed. the vehicle was towed from the scene. the contact stated that there was minor damage to the vehicle. a police report was filed. the vehicle has not been inspected. the purchase date was unknown. the current and failure mileages were 78,000.
- Tires › Sidewall
There was no event that was noted that would cause the separation of the tire tread from the sidewall. A major leak was noted. The split was located at the point of sidewall to tread joint. The tire has >9/32 of tread left on the tire. I am at a loss to replace the tire. No trauma was inflicted on the tire. *nm
- Parking brake
This complaint IS regarding nhtsa ID # 05v161000 and gm recall # 05042. The above IS for a defect in the parking brake which causes premature wear. The recall only applies to manual shift transmissions. I have this same problem but have an automatic transmission. I believe this recall should also…
This complaint IS regarding nhtsa ID # 05v161000 and gm recall # 05042. The above IS for a defect in the parking brake which causes premature wear. The recall only applies to manual shift transmissions. I have this same problem but have an automatic transmission. I believe this recall should also apply to my vehicle since a parking brake IS also installed on my vehicle and it IS also defective. If a parking brake IS not needed on my vehicle for safety than why IS one installed? *jb
- Parking brake › Driveline › Hydraulic › Hoses, lines/piping, and fittings
The parking brake was on and the vehicle was parked on a slight incline and without warning the vehicle rolled down the street and crashed into a tree. vehicle was towed to the dealer for inspection, and mechanic determined that the brake pads needed to be replaced on the parking brakes due to wear and tear. *ak
- Air bags
Airbags did not deploy when vehicle went off road and rashed; on-star did not function either manually or upon impact.*ak
- Parking brake
Dealership informed the consumer that the emergency parking brake wore out. This could potentially cause the vehicle to roll back/forward on a incline without warning. dealership was not able to resolve the problem. *Ak retainer on emergency brake failed. *la
- Tires › Tread/belt
While driving approximately 55 mph rear right tire blew out. consumer managed to pull vehicle over, and stopped to check the tire. Noticed that tread had separated from the right rear tire. Bridgestone tire, size 285/75r16. *Ak
- Engine and engine cooling › Exhaust system
While driving the consumer smelled fumes inside the vehicle. the dealer was notified. *nlm
- Suspension › Front
Consumer states while driving at highway speed the vehicle pulls violently to the right. *nlm *dt
- Fuel system, gasoline
A fuel leak underneath vehicle. Vehicle has not been inspected by dealership. Please provide additional information.*ak
- Suspension · Visibility › Rearview mirrors/devices › Exterior
Vehicle bounces all over the road, both outside mirrors vibrate due to this. Dealer has balanced tires, did not remedy the problem. Please provide additional information.*ak
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- 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
- 10246645Pre-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.
- 10242298This 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
- 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.
- 10237671This 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.
- 10237648This 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.
- 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
Every GMC Sierra 3500 model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.