Model year record

2002 GMC Sierra 3500 recalls & problems

The 2002 GMC Sierra 3500 has 3 safety recalls and 20 owner complaints on file with NHTSA. The most-reported problem area is service brakes (4 complaints).

Recalls3safety recalls

Complaints20filed by owners

Crashes · fires3 · 1reported in complaints

Injuries · deaths1 · 0reported in complaints

Safety recalls

Fuel system, gasolineMay 19, 2006

Fuel system, gasoline

Recall 06E04300088,303 vehicles

Problem: 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, CLICK ON "DOCUMENT SEARCH" AND THEN "BUS APPLICATIONS"). THE CONNECTOR ON THE FUEL FILTER WAS NOT MANUFACTURED TO HONEYWELL'S SPECIFICATION. AS A RESULT, THE O-RING MAY NOT SEAT CORRECTLY ON THE FUEL LINE.
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.
Fix: 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).

Equipment adaptive/mobilityNov 26, 2004

Equipment adaptive/mobility

Recall 04V5620001,660 vehiclesopened after NHTSA action (ODI)

Problem: ON CERTAIN VANS EQUIPPED WITH SURE-LOK WHEELCHAIR SECUREMENT SYSTEMS, THE SPROCKET TEETH OF THE RETRACTOR ASSEMBLY IS OUT OF ALIGNMENT.
Risk: IN THE EVENT OF A VEHICLE CRASH, THE WHEELCHAIR MAY NOT BE ADEQUATELY SECURED POSSIBLY RESULTING IN INJURIES TO A WHEELCHAIR OCCUPANT.
Fix: 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.

Interior lightingJun 26, 2001

Interior lighting

Recall 01V22000038,863 vehicles

Problem: 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 NOT MEET THE PARTIAL SYSTEM REQUIREMENTS OF FMVSS NO. 105.
Risk: THESE CONDITIONS COULD RESULT IN REDUCED BRAKING CAPABILITY, WHICH COULD LEAD TO A CRASH.
Fix: 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.

Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.

What owners report

Problem area	Complaints	Crashes	Fires	Injuries	Typical mileage*
Service brakes	4	0	0	0	137,000 mi
SuspensionFront	3	0	0	0	—
Parking brakeDriveline › Hydraulic › Hoses, lines/piping, and fittings	3	1	0	0	—
Service brakes, hydraulic	3	0	0	0	49,100 mi
Fuel/propulsion system	3	0	0	0	101,000 mi
Fuel system, gasoline	2	0	1	0	—
TiresTread/belt; Sidewall	2	0	0	0	—
Air bagsFrontal	2	2	0	1	—
Fuel system, diesel	2	0	0	0	—
VisibilityRearview mirrors/devices › Exterior	1	0	0	0	—
Engine and engine coolingExhaust system	1	0	0	0	—
Vehicle speed control	1	0	0	0	—

*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.

Recent owner 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 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.
Apr 15, 2016 · 120,000 miles
Service brakes
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.
Mar 2, 2015 · 101,000 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 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…
Jun 17, 2014 · 85,118 miles
Service brakes
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
Jul 19, 2013 · 137,000 miles
Fuel system, diesel
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.…
Apr 14, 2012 · 154,163 miles
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 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
Jul 12, 2012
Fuel system, gasolineFire
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.
Feb 1, 2010 · 80,000 miles
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 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.
Sep 28, 2008 · 49,100 miles

Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.

NHTSA defect investigations

HYDRAULIC PUMP SHAFT FAILURESClosed
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…
PE04004 · opened Jan 8, 2004 · closed Apr 30, 2004