Model year record

2002 GMC Sierra recalls & problems

The 2002 GMC Sierra has 7 safety recalls and 249 owner complaints on file with NHTSA. The most-reported problem area is service brakes, hydraulic (100 complaints).

Recalls7safety recalls

Complaints249filed by owners

Crashes · fires23 · 2reported in complaints

Injuries · deaths6 · 0reported in complaints

Safety recalls

Exterior lightingMay 11, 2009

Headlights

Recall 09E02500042,540 vehiclesopened after NHTSA action (OVSC)

Problem: 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 THE REQUIRED AMBER SIDE REFLECTORS.
Risk: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
Fix: 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.

EquipmentAug 28, 2007

Electrical

Recall 07E066000175 vehicles

Problem: 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: IF THE TRAILER LIGHTS ARE NOT WORKING PROPERLY, A VEHICLE CRASH CAN OCCUR.
Fix: ALL OF THE DEFECTIVE TOW PACKAGES ARE STILL AT THE DISTRIBUTOR LEVEL AND HAVE NOT BEEN SOLD TO ANY CONSUMERS.

Service brakes, hydraulicAug 29, 2005

Antilock/traction control/electronic limited slip

Recall 05V3790001,353,718 vehiclesopened after NHTSA action (ODI)

Problem: 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, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN AND THE DISTRICT OF COLUMBIA ONLY.
Risk: THIS CAN CAUSE INCREASED STOPPING DISTANCES DURING LOW-SPEED BRAKE APPLICATIONS, WHICH COULD RESULT IN A CRASH.
Fix: 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.

Parking brakeApr 22, 2005

Parking brake

Recall 05V16100090,242 vehiclesopened after NHTSA action (ODI)

Problem: 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: IF THE PARKING BRAKE DOES NOT HOLD, UNINTENDED VEHICLE MOVEMENT COULD OCCUR, WHICH COULD RESULT IN A CRASH.
Fix: 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.

EquipmentMar 23, 2004

Equipment

Recall 04E0220008,000 vehicles

Problem: 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: THE BEDLINER CAN BECOME DETACHED FROM THE PICKUP WHILE IT IS MOTION, POSSIBLY ENDANGERING FOLLOWING MOTORISTS OR PEDESTRIANS.
Fix: 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.

StructureMar 17, 2004

Body › Tailgate › Hinge and attachments

Recall 04V1290003,662,211 vehiclesopened after NHTSA action (ODI)

Problem: 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: 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.
Fix: 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.

Fuel system, otherNov 3, 2003

Delivery

Recall 03V435000395 vehicles

Problem: 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: 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.
Fix: 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.

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.

Crash test ratings

2002 GMC Sierra Extended Cab

OverallNot Rated

Frontal crash	Not Rated
Side crash	Not Rated
Rollover	★★★★★

NHTSA 5-Star Safety Ratings (New Car Assessment Program). Ratings are comparable only between vehicles of similar size and weight, and ratings from 2011 on use tougher tests than earlier years. Photos: NHTSA.

What owners report

Problem area	Complaints	Crashes	Fires	Injuries	Typical mileage*
Service brakes, hydraulicAntilock/traction control/electronic limited slip; Foundation components › Disc › Rotor	100	13	0	3	39,825 mi
Service brakes	31	4	0	1	117,142 mi
Engine and engine coolingEngine; Engine › Gasoline	22	0	1	0	24,000 mi
StructureBody › Tailgate › Hinge and attachments; Body	18	1	0	2	41,000 mi
Power trainAutomatic transmission; Clutch assembly	18	0	0	0	39,000 mi
Parking brake	17	0	0	0	30,000 mi
SuspensionRear; Front › Wheel bearing	12	1	0	0	35,000 mi
SteeringHydraulic power assist system; Hydraulic power assist › Pump	12	2	0	0	40,000 mi
TiresSidewall; Tread/belt	11	0	1	0	33,087 mi
VisibilityRearview mirrors/devices; Rearview mirrors/devices › Exterior	6	0	0	0	33,500 mi
Electrical system12v/24v/48v battery; Wiring	6	0	0	0	64,000 mi
Seat beltsFront	4	0	0	0	99,800 mi

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

Recent owner 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.
Jan 1, 2016 · 100,000 miles
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 REPAIR. THE MANUFACTURER WAS NOTIFIED OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE. VIN TOOL CONFIRMS PARTS NOT AVAILABLE.
Dec 3, 2015
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 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.
Oct 20, 2015 · 73,300 miles
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 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…
Aug 21, 2015
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 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.
Jul 21, 2015 · 116,301 miles
Engine
THE PASSENGER SIDE REAR EXHAUST MANIFOLD BOLT BROKE OFF. THIS IS A MANUFACTURER DEFECT. THIS IS A VERY COMMON PROBLEM WITH THESE TRUCKS.
May 27, 2015 · 115,500 miles
Service brakes
APPLIED BRAKES TO STOP AND BRAKE PEDDLE WENT TO FLOOR DO TO ROTTED BRAKE LINE. *TR
Feb 28, 2015 · 117,984 miles
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
Feb 27, 2015 · 216,000 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

Brake line corrosion failureClosed
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…
PE10010 · opened Mar 30, 2010 · closed Jan 5, 2011
CRANK POSITION SENSOR FAILURE - STALLClosed
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…
PE06016 · opened May 4, 2006 · closed Sep 14, 2006
PARKING BRAKE FAILUREClosed
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.
DP05009 · opened Dec 20, 2005 · closed May 31, 2006
UNWANTED LOW-SPEED ABS ACTIVATIONClosedLed to recall 05V379000
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…
PE05020 · opened Apr 28, 2005 · closed Sep 13, 2005
PARKING BRAKE FAILUREClosedLed to recall 05V161000
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…
EA04011 · opened Apr 9, 2004 · closed May 10, 2005
TAILGATE CABLE BREAKAGEClosedLed to recall 04E067000
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.
EA04005 · opened Feb 19, 2004 · closed Sep 28, 2004
PARKING BRAKE FAILUREClosed
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…
PE03057 · opened Dec 8, 2003 · closed Apr 9, 2004
THROTTLE STICKING CLOSEDClosed
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…
EA02015 · opened Aug 1, 2002 · closed Jan 12, 2004