2002 GMC Sierra 2500 Problems

What owners report

Complaints for this model year cluster heavily around the braking system, and the dominant theme is rusted steel brake lines that burst and let the pedal drop to the floor, usually with little or no warning. A second brake concern is early ABS activation at low speeds with corroded front hubs and sensors. Outside the brakes, owners describe engines quitting at speed traced to the crankshaft position sensor, and transmission cooler lines rusting through. The truck is now well past 20 years old, so many of these reports come from corrosion-prone, road-salt climates and from vehicles with high mileage, though several owners describe line or sensor problems at relatively low mileage.

1. 1
   Brakes

   Rusted brake lines bursting, pedal to the floor

   • 49 complaints (37%)
   • median 100,108 mi at 10.0 yrs old (47 state mileage)
   • 6 mention a crash, fire or injury
   • filed 2003–2015

   Owners describe pressing the brake pedal and having it drop straight to the floor, sometimes with a hiss and brake fluid visible on the ground or sprayed on the frame. Mechanics in the complaints trace it to brake lines that are heavily rusted, often above the driver's side or near the ABS unit, and in most cases the whole set of lines is replaced rather than one section. Several owners note that the pedal went down without any warning light, and some report the same failure more than once at different lines. Most reports sit between roughly 50,000 and 150,000 miles, though a few owners describe a first line letting go under 30,000 miles.

   Recall 01V220000

   What to check: Get the truck on a lift and look at the steel lines running the length of the frame and around the ABS unit for scale and pitting, and ask whether any were replaced. If the brake fluid reservoir is low, find out where it went before driving.

   2 excerpts from owner complaints in NHTSA records

   “I have a 2002 Gmc SIERRA 2500 diesel. I have a had several problems with the brake lines rotting out. This truck only has 84000 miles on it. Last week my family and I where out driving and the brakes went all the way to the floor at and through a red light. I pulled over safely and inspected the truck and found yet another brake line ruptured..”

   NHTSA complaint #10294336, filed 2009-12, 86,000 miles

   “Pulling out of my driveway onto the street. Applied the brakes when reaching the end of the driveway and brake pedal when completely to the floor. Was able to stop, being that I was only going around 2 MPH at the time. When I got out of the truck, I saw a large amount of brake fluid on the driveway from a burst brake line.”

   NHTSA complaint #10652609, filed 2014-11, 145,000 miles
2. 2
   Brakes

   ABS engages at low speed; corroded hubs and sensors

   • 22 complaints (16%)
   • median 67,000 mi at 6.5 yrs old (21 state mileage)
   • filed 2005–2017

   Owners report the ABS kicking in during ordinary low-speed stops, with the pedal pulsating, the truck skidding or pulling to one side, and stopping distances getting longer. In complaints where the truck was inspected, front wheel hubs and ABS sensors were found corroded or replaced, and one owner was told the rotors were corroded and water had collected in the hubs. Some owners say they were told their 3/4-ton truck was not covered by a campaign that addressed the same symptom on other models. Reported from a few thousand miles up to roughly 110,000 miles, with several complaints filed under 50,000 miles.

   What to check: Drive slowly on a wet or loose surface and feel for the ABS cycling when it should not, and have the front hubs and wheel speed sensors checked for rust and play. Ask whether hub assemblies or sensors have already been replaced.

   2 excerpts from owner complaints in NHTSA records

   “Gm recall #05068 anti- lock causing increased stopping distances, GM is only repairing this problem on 1/2 ton products due to the fact it is a simple inexpensive repair. I own a 3/4 ton truck with the exact same problem but due to the fact a repair consists of replacement of the front wheel bearings they (GM) have chosen not to include 3/4 ton in this recall. I have on several occasions had increased stopping distances due to the sensor failure, my dealership said they can repair GM's defect at a price of $800.00 to me.”

   NHTSA complaint #10140116, filed 2005-10, 40,000 miles

   “Upon braking up to a stop sign for instance. The vehicles ABS will kick in at the last minute releasing the left front wheel causing the vehicle to dive to the right. This happens in wet or dry condition but is particularly bad in icy conditions.”

   NHTSA complaint #10175650, filed 2006-12, 70,000 miles
3. 3
   Engine cooling

   Engine quits at speed (crankshaft position sensor)

   • 6 complaints (4%)
   • median 53,500 mi at 5.2 yrs old (6 state mileage, few)
   • filed 2006–2011

   Owners describe the engine shutting off without warning while driving at highway speed or in gear, sometimes restarting before the truck stops and sometimes cranking without starting for several minutes. In the complaints the crankshaft position sensor is the part replaced, and owners note that steering and brake assist feel harder once the engine stops. Several owners point out that an earlier model year was recalled for the same symptom and ask why this model year was not included. Mostly reported between about 30,000 and 90,000 miles, described as happening during normal driving rather than at start-up.

   What to check: Ask whether the crankshaft position sensor has been replaced and when; a scan tool can show pending codes for it. If the engine has cut out before, have the sensor and its wiring checked before relying on the truck for long trips.

   2 excerpts from owner complaints in NHTSA records

   “I have a 2002 Gmc sierra 2500hd pickup with the vortec 8.1 engine. I am experiencing the same crank position sensor failure as experienced in the 2001 model year recall (safety recall # 06083). I am not alone, as many many others are having the same issues in their 2002-2004 pickup trucks. I believe the NHTSA should extend safety recall # 06083 to include model years 2002 to 2004, as some models manufactured in canada frequently use parts from previous us model years. My vehicle is not safe to operate on the highways as a result. Please advise. …”

   NHTSA complaint #10232980, filed 2008-07, 52,000 miles

   “2002 Gmc sierra stalls while at freeway speeds and normal driving. 2 near accidents, sometimes the engine will crank with a no start condition. Killed one of my AC delco batteries. Had to replace battery and crank position sensor.”

   NHTSA complaint #10159068, filed 2006-06, 55,000 miles
4. 4
   Transmission and drivetrain

   Transmission cooler lines rusting through

   • 6 complaints (4%)
   • median 124,260 mi at 8.6 yrs old (6 state mileage, few)
   • filed 2006–2017

   Owners report fluid pooling under the truck and, in one case, a truck that would not move at all because the transmission had lost its fluid. In the complaints the cause is a transmission cooler line rusted through, with one owner noting corrosion at the metal retaining clip, and owners frequently compare it to the brake lines rusting in the same way. Repairs described are hose or line replacement, and one owner reported a hole worn through the transfer case that was sealed with a patch. Generally reported past 50,000 miles, up to around 140,000 miles, and usually first noticed as a puddle under the vehicle.

   What to check: Check the transmission cooler lines and their mounting clips along the frame and radiator for rust and wet spots, and confirm the fluid level and colour on the dipstick. A fresh drip or fluid smell under the truck is worth having a shop trace before buying.

   2 excerpts from owner complaints in NHTSA records

   “First the transmission cooling lines rusted out costing over 400.00 to repair. Today the brake lines failed because of rust. This will be a very expensive repair. I was fortunate that I was able to avoid crashing the truck when the brakes failed.”

   NHTSA complaint #10471448, filed 2012-08, 138,000 miles

   “Went out to the truck to go to work and the truck wouldn't move. Transmission line leaking out all fluid. Corroded and had to be replace just like the brake lines.”

   NHTSA complaint #10324863, filed 2010-04, 117,000 miles

Buying note. This model year's complaints are dominated by corrosion of steel brake and transmission cooler lines, so a pre-purchase inspection should include a close look underneath for rust on these lines, in addition to the usual checks on the crankshaft position sensor history and front wheel hubs.

Summary written with AI from a sample of 60 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.