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2002 problems

FaultScore report

2002 GMC Sierra 3500 problems

Owners have filed 29 complaints about the 2002 GMC Sierra 3500 with NHTSA between 2002 and 2016. The largest single group is the brakes. Across this model's run it ranks 10 of 26 worst.

Read the complaints What breaks Worst years for the GMC Sierra 3500 All 2002 cars

FaultScore 57/100

Higher is worse. Measured against the other years of the GMC Sierra 3500.

How this is worked out

The numbers

Complaints

Crashes reported

Fires reported

Injuries reported

101,000 mi

Median mileage at failure

Half of reported failures happened before this

14%

Failed under 36,000 miles

Inside a typical bumper-to-bumper warranty

What kind of bad

The letter says how bad. This says what kind — whether this year drew an unusual number of complaints, unusually dangerous ones, or failures that arrived unusually early.

The dashed ring is 50 — the national norm. Further out is worse.

Complaint volume — 51: Against the median year of the GMC Sierra 3500. 50 means typical for this model; 100 means roughly double.
Severity — 89: 17.2% of these complaints involved a crash, fire, injury or death, against a national rate of 9.7%.
Early failure — 23: 14% of failures with a mileage on record happened under 36,000 miles, against a national rate of 29%.

How 2002 compares with every other GMC Sierra 3500

Click any bar to open that year's report.

2 15 12 25 30 44 29 9 29 29 14 19 28 8 2 24 15 15 10 40 27 18 20 20 72 28 44 45 66 25 5

96 97 98 99 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Complaints filed with NHTSA, by model year. Bar colour is the FaultScore grade: A B C D F ungraded

What breaks on a 2002 GMC Sierra 3500

Every complaint is filed against a part. Follow any row for the complaints about that part alone.

Brakes 10 34.5%

1 crashes, 0 fires · median 80,000 mi

Fuel & Propulsion 7 24.1%

0 crashes, 1 fires · median 119,000 mi

Suspension 3 10.3%

Median failure at 137,000 miles

Tires 2 6.9%

Median failure at 59,344 miles

Airbags 2 6.9%

2 crashes, 0 fires · median 52,500 mi

Engine & Cooling 2 6.9%

Median failure at 120,000 miles

Other & Unspecified 1 3.4%

Median failure at 101,000 miles

Windows, Mirrors & Wipers 1 3.4%

Acceleration & Cruise Control 1 3.4%

Median failure at 154,163 miles

When it fails

Odometer readings owners gave when they filed. About half of all complaints include one.

10,000 – 24,999 miles 1 4.5%

25,000 – 49,999 miles 4 18.2%

50,000 – 74,999 miles 1 4.5%

75,000 – 99,999 miles 4 18.2%

100,000 – 149,999 miles 7 31.8%

150,000+ miles 5 22.7%

When owners complained

A spike years after the car went on sale usually means a part wearing out on schedule across the whole fleet — the kind of pattern no single owner can see from inside their own car.

Aug 2002 peak 5 Apr 2016

NHTSA investigations into the 2002 GMC Sierra 3500

An investigation is the step before a recall: the agency has seen enough complaints to look into a pattern itself. An open one means it thinks something may be wrong and nothing has been fixed yet.

PE04004 Opened 8 Jan 2004 Closed 30 Apr 2004 SERVICE BRAKES, HYDRAULIC

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 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 AN...

Recalls on the 2002 GMC Sierra 3500

A complaint is one owner's allegation. A recall is the point at which the manufacturer or a regulator agreed the defect is real and dangerous enough to fix for free — however old the car is.

United States — NHTSA

06E043000 19 May 2006

FUEL SYSTEM, GASOLINE

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.

04V562000 26 Nov 2004

EQUIPMENT ADAPTIVE/MOBILITY

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.

01V220000 26 Jun 2001

INTERIOR LIGHTING

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.

Recalls cover specific build ranges, so check your own vehicle by VIN at nhtsa.gov/recalls or, in Canada, Transport Canada.

Complaints that involved harm

Reports where the owner recorded a crash, a fire, an injury or a death.

Filed 19 Jan 2011 at 80,000 miles Gaffney, SC Fire

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 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.

NHTSA complaint #10377169 — an unverified report by a vehicle owner.

Filed 16 Oct 2007 at 78,000 miles Clucksville, TN Crash

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.

NHTSA complaint #10205813 — an unverified report by a vehicle owner.

Filed 23 Mar 2005 Blue Ridge, GA Crash

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.

NHTSA complaint #10115704 — an unverified report by a vehicle owner.

Filed 8 Apr 2004 at 27,000 miles Lincoln, NE Crash 1 injured

AIR BAGS

AIRBAGS DID NOT DEPLOY WHEN VEHICLE WENT OFF ROAD AND RASHED; ON-STAR DID NOT FUNCTION EITHER MANUALLY OR UPON IMPACT.

NHTSA complaint #10065803 — an unverified report by a vehicle owner.

The most recent complaints

In the owners' own words, exactly as filed with NHTSA.

Filed 22 Apr 2016 at 120,000 miles Etna, ME

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.

NHTSA complaint #10860980 — an unverified report by a vehicle owner.

Filed 30 Oct 2015 at 101,000 miles Little Valley, NY

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.

NHTSA complaint #10787186 — an unverified report by a vehicle owner.

Filed 30 Oct 2015 at 101,000 miles Little Valley, NY

SERVICE BRAKES

NHTSA complaint #10787186 — an unverified report by a vehicle owner.

Filed 30 Oct 2015 at 101,000 miles Little Valley, NY

FUEL/PROPULSION SYSTEM

NHTSA complaint #10787186 — an unverified report by a vehicle owner.

Filed 30 Jun 2015 at 85,118 miles Clovis, CA

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 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

NHTSA complaint #10731304 — an unverified report by a vehicle owner.

Filed 21 Jul 2013 at 137,000 miles York, PA

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 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.

NHTSA complaint #10526003 — an unverified report by a vehicle owner.

Filed 21 Jul 2013 at 137,000 miles York, PA

FUEL SYSTEM, DIESEL

NHTSA complaint #10526003 — an unverified report by a vehicle owner.

Filed 21 Jul 2013 at 137,000 miles York, PA

SERVICE BRAKES

NHTSA complaint #10526003 — an unverified report by a vehicle owner.

Filed 11 Feb 2013 at 154,163 miles Cold Spring, KY

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 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.