2002 GMC Sierra 3500

Routine

Owners filed 20 complaints about this vehicle with federal regulators, most often about the service brakes. It has been recalled 3 times.

What fails
ComponentReportsCrashesFiresInjuries
Service Brakes3
000
Service Brakes, Hydraulic2
000
Parking Brake2
000
Fuel System, Gasoline2
010
Tires › Tread/Belt1
000
Tires › Sidewall1
000
Suspension › Front1
000
Suspension1
000
Parking Brake › Driveline › Hydraulic › Hoses, Lines/Piping, and Fittings1
100
Fuel/Propulsion System1
000

3 safety recalls

Part 573 reports
Fuel System, Gasoline06E043000
Filed May 19, 200688,303 vehiclesHoneywell International, Inc.

Defect. 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.

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).

Equipment Adaptive/Mobility04V562000
Filed Nov 26, 20041,660 vehiclesMobility Works

Defect. 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.

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.

Interior Lighting01V220000
Filed Jun 26, 200138,863 vehiclesGeneral Motors Corp.

Defect. 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.

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.

What owners reported

Newest filings
Engine
Filed Apr 22, 2016120,000 milesME

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.

Service Brakes
Filed Oct 30, 2015101,000 milesNY

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
Filed Jun 30, 201585,118 milesCA

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

Service Brakes
Filed Jul 21, 2013137,000 milesPA

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 System, Diesel
Filed Feb 11, 2013154,163 milesKY

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
Filed Jul 12, 2012IL

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, GasolineFire
Filed Jan 19, 201180,000 milesSC

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
Filed Jan 27, 200949,100 milesCT

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
Filed Jul 1, 200842,050 milesMI

MY ABS BRAKES PREVENT MY TRUCK FROM STOPPING AT SLOW SPEEDS. *TR

Air Bags › FrontalCrash
Filed Oct 16, 200778,000 milesTN

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
Filed Oct 20, 200688,689 milesTN

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
Filed Sep 19, 200620,000 milesCA

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 FittingsCrash
Filed Mar 23, 2005GA

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

Parking Brake
Filed May 11, 200459,000 milesCO

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

Air BagsCrash1 injured
Filed Apr 8, 200427,000 milesNE

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

Tires › Tread/Belt
Filed Sep 23, 200330,000 milesCA

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
Filed Apr 18, 2003KY

WHILE DRIVING THE CONSUMER SMELLED FUMES INSIDE THE VEHICLE. THE DEALER WAS NOTIFIED. *NLM

Suspension › Front
Filed Jan 9, 2003IA

CONSUMER STATES WHILE DRIVING AT HIGHWAY SPEED THE VEHICLE PULLS VIOLENTLY TO THE RIGHT. *NLM *DT

Suspension
Filed Aug 13, 2002IN

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

Fuel System, Gasoline
Filed Aug 13, 2002IN

A FUEL LEAK UNDERNEATH VEHICLE. VEHICLE HAS NOT BEEN INSPECTED BY DEALERSHIP. PLEASE PROVIDE ADDITIONAL INFORMATION.*AK

20 of 20 complaints, reproduced as filed.

Across model years

Worst on record: 2020
YearComplaintsRecallsFiresDeathsAssessment
20264200Routine
202516100Routine
202444310Routine
202328100Routine
202231300Routine
202120500Routine
202051820Routine
201913710Routine
201814600Routine
201713710Routine
201619600Routine
201531710Routine
20147300Routine
201314400Routine
20129400Routine
201120510Routine
20102500Routine
20095500Routine
200825300Routine
200716310Routine
200611010Routine
200524110Routine
200424120Routine
20037100Routine
2002 — this page20310Routine
200136310Routine
200026411Fatalities reported
199919300Routine
199812420Routine
199710300Routine
19961000Routine

Compare every Sierra 3500 year →

Reading this record

No unusual pattern of severe incidents in the complaint record.

Complaint counts track how many cars were sold and how long they have been on the road as much as they track quality. A common model from 2013 has had a decade to accumulate reports; a rare one from last year has not. The signal worth weighing is in the severity columns, in whether the same component keeps appearing, and in whether the manufacturer eventually opened a recall for it.

Recall repairs are free for as long as the recall stands. Check whether a specific car still has open work at NHTSA's VIN lookup.

Most recent recall on file: May 19, 2006. Source: NHTSA Office of Defects Investigation.