2002 Chevrolet Silverado 3500 Problems

What owners report

Owners of this model year most often describe brake problems, including brake lines that rusted or ruptured and anti-lock brakes that engage at low speed. Engines that shut off or stall while driving and fuel injector failures also come up often, and many complaints mention rust or corrosion. Most complaints state mileage, which ranges from 500 to about 160,000 miles, and several owners say a related recall did not cover their VIN.

1. 1
   Brakes

   Rusted or ruptured brake lines and fluid loss

   • 13 complaints (26%)
   • median 62,000 mi at 9.6 yrs old (11 state mileage)
   • 3 mention a crash, fire or injury
   • filed 2004–2018

   Owners describe brake lines that rusted through or ruptured, leaking brake fluid and causing a loss of braking. One says the brakes were lost with no warning while hooking up a camper, and another says the pedal went to the floor without the vehicle stopping. Several complaints describe steel lines that rusted out, and one mentions uncoated steel brake lines. Where mileage is stated, these reports range from about 41,500 to 160,000 miles, and all were filed between 2011 and 2018.

   Recall 01V220000

   What to check: Look under the truck along the frame and at the ABS unit for rust, leaks, or wet spots on the brake lines. Ask whether the brake fluid level has been checked, and whether the recall for the brake system warning light has been checked against this truck's VIN.

   2 excerpts from owner complaints in NHTSA records

   “When positioning my truck to hook up my 5th wheel camper I lost my brakes. There was no warning of any kind and I wasn't sure until I got out and saw the puddle . Even after moving the truck an losing more fluid there was still no warning. I hate to think if had hooked up and been down the highway when corroded metal lines blew out!”

   NHTSA complaint #10870694, filed 2016-05, 145,000 miles

   “Brake line failure. Coming to stop light, brakes went out causing me to run the light almost causing major accident. This happened in feb 2013. Had brake line repaired. In june 2013 same thing happened again / different brake line. Need to replace all brake lines.”

   NHTSA complaint #10522456, filed 2013-06, 160,000 miles
2. 2
   Engine cooling

   Engine shuts off or stalls while driving

   • 14 complaints (28%)
   • median 34,000 mi at 4.9 yrs old (13 state mileage)
   • 2 mention a crash, fire or injury
   • filed 2003–2014

   Owners describe engines that shut off or stall while driving, sometimes at highway speed or while stopped in traffic, often without warning. Some say the engine would not restart, and one describes losing power steering and brake power while coasting to the side of the road. Some owners say repairs, including a fuel filter replacement, did not stop the shutoffs, and the dealer could not duplicate the failure in one case. Each of these complaints lists mileage, from 500 to about 62,000 miles.

   What to check: Ask for repair records and any diagnostic trouble codes for shutoffs, stalling, or crankshaft sensor work, since several complaints describe repeat repairs. On a test drive, confirm the engine restarts smoothly and that the dashboard shows no warning lights.

   2 excerpts from owner complaints in NHTSA records

   “My truck has the new duramax engine in it. And it has had the fuel injectors go out 4 times. I feel like I live at the Chevrolet dealership at times. The bad thing about this engine is when the motor has a problem it shuts down. And if your on a freeway your going to be ran over. It shuts down anywhere at anytime and you cannot start it.”

   NHTSA complaint #10018330, filed 2003-05, 46,000 miles

   “While driving the vehicle just completely shuts off, I have replaced everything & 1 year later and 25,000 miles later & 5 accidents the vehicle still does it now it wont even start. This is very dangerous and there should be a re-call on this I've read that this is very common in this vehicle and there are various recalls on the wiring harness, transmission, fuel line, filter, headlights, towing package, brake system, brake lights, brake warning lights. Everybody who is experiencing this issue should file a complaint to resolve this issue. …”

   NHTSA complaint #10658664, filed 2014-11, 40,213 miles
3. 3
   Brakes

   Anti-lock brakes engage at low speed

   • 7 complaints (14%)
   • median 39,500 mi at 4.4 yrs old (6 state mileage, few)
   • filed 2005–2010

   Owners describe anti-lock brakes that engage during normal stops at about 5 to 10 mph, with longer stopping distances, a loss of braking, or brakes that push back without slowing the truck. Some complaints point to corroded or failed wheel speed sensors, and one says the power steering cut out during these events. Several owners say a related recall did not cover their VIN, and one paid for the repair at their own expense. Where mileage is stated, these complaints describe about 19,000 to 56,000 miles, and all were filed between 2005 and 2010.

   What to check: Ask whether the wheel speed sensors have been inspected for corrosion, especially on trucks used in salt-belt states. Check the VIN against the anti-lock brake recall described in these complaints, since some owners were excluded by VIN.

   2 excerpts from owner complaints in NHTSA records

   “Under normal braking conditions the anti lock braking system will activate at low speed, around 7-10 miles per hour. Contacted local dealer and they told me it was typically the wheel speed sensor that causes this problem. There was a recall issued by GM but my truck did not fall in this recall due to the VIN number. Wheel speed sensors were replaced to fix this issue.”

   NHTSA complaint #10198697, filed 2007-08, 56,000 miles

   “Anti-lock braking system consistently engages when at slow-speed stopping (5-8 MPH). Problem started at the 40,000 mile mark. Dealer informed that there is a recall on the issue but my VIN does not qualify.”

   NHTSA complaint #10357983, filed 2010-09, 40,000 miles
4. 4
   Suspension

   Vibration, bounce, or sway while driving

   • 5 complaints (10%)
   • median 45,176 mi at 3.9 yrs old (2 state mileage, few)
   • filed 2002–2008

   Owners describe vibration, bounce, or sway that continued after dealer repair attempts, including tire balancing and suspension checks. One owner says the dealer later reported nothing wrong with the vehicle, and another describes a flywheel that rattled and vibrated after an earlier replacement. Another complaint describes excessive vibration at highway speed, with a tire blistering on the sidewall. Where mileage is stated, these complaints range from about 3,350 to 87,000 miles, and the others give none.

   What to check: On a test drive at highway speed, check for vibration, bounce, or wander, and ask for records of any balancing, axle, or flywheel work. Several complaints describe repeat attempts that did not resolve the symptom, so ask what was done and when.

   2 excerpts from owner complaints in NHTSA records

   “Loss of control due to an unknown jiggle/bounce, out of balance condition. Consumer felt dealership lacked technical abilities to diagnose problem. To date vehicle had 14 different new tires on the rear axle. Vehicle had been serviced 10 times. The tire pressure was adjusted, the front and rear suspension checked. Rear sway bar was unhooked. Tires were balanced. However problem still existed. There was also poor fuel mileage and an exhaust odor. Due to safety issues consumer is reluctant to drive vehicle.”

   NHTSA complaint #10009506, filed 2003-03, 3,352 miles

   “While driving vehicle has a bumpy vibration and tends to run off the road. Dealer attempted to repair vehicle but did not succeed and now stating that nothing is wrong with the vehicle. Please provide additional information. Ts”

   NHTSA complaint #10001913, filed 2003-01
5. 5
   Fuel system

   Fuel injectors fail repeatedly or leak

   • 5 complaints (10%)
   • median 66,500 mi at 4.0 yrs old (4 state mileage, few)
   • filed 2003–2018

   Owners describe fuel injectors that failed repeatedly, in some cases several times on the same truck. One complaint describes fuel leaking while driving, a hairline crack in the fuel rail, and fuel getting into the crankcase. One describes exhaust smoke from a fuel injector that had already been replaced three times. Where mileage is stated, these complaints range from about 43,700 to 152,900 miles, and they were filed between 2003 and 2018.

   What to check: Ask for the repair history of the fuel injectors and fuel rail, and check the engine bay and underside for fuel odor, wet spots, or leaks.

   2 excerpts from owner complaints in NHTSA records

   “While driving the consumer noticed that the vehicle was leaking fuel. The fuel caused poor visibility to motorist driving behind his vehicle. The dealership determined that the fuel injection needed to be replaced. The vehicle is now on it's fourth repair. The fuel leak could cause to pushed past the piston rings into the crankcase, and a hairline crack in the fuel rail also caused fuel into the crankcase. Also, the leak of fuel and oil has caused check engine light to turn on. …”

   NHTSA complaint #10059341, filed 2004-04, 43,688 miles

   “2002 Chevrolet silverado. Consumer writes in regards to several fuel injector failures and oem uncoated carbon steel brake lines. *m the consumer stated GM withheld material facts concerning duramax lb7 diesel fuel injector failures in violation of missouri merchandising practices act at the time of sale and delivery.”

   NHTSA complaint #10855736, filed 2018-01

Buying note. Buyers may want to check the brake lines and fluid for rust and leaks, and test drive for anti-lock braking behavior at low speed. Because several complaints describe engine shutoffs and repeated fuel injector failures, repair records for these systems are worth requesting before purchase.

Summary written with AI from a sample of 48 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.