2002 GMC Sierra Problems

What owners report

Complaints about this model year cluster heavily around the brakes: unwanted or failed antilock brake activity at low speed and corroded brake lines are the most common themes, and many owners mention that a related ABS recall did not cover their truck because of where they live. Powertrain complaints are fewer and spread across stalling, transmission shifting and cooling issues. Many reports arrive at moderate mileage, though some brake complaints come in very early.

1. 1
   Brakes

   ABS activates or cuts out at low speed, poor stopping

   • 68 complaints (27%)
   • median 40,000 mi at 3.7 yrs old (60 state mileage)
   • 12 mention a crash, fire or injury
   • filed 2002–2015

   Owners describe the antilock system kicking in by itself during slow stops or over bumps, with a pulsating or ratcheting pedal and the truck rolling past the intended stopping point. Some say the condition got more frequent over time and that removing the ABS fuse or having wheel speed sensors replaced was the only way to restore normal braking, and that the problem returned afterward. Several note the truck was not covered by the ABS recall because of its VIN or the state it was registered in, and dealers often reported no stored codes or said the brakes were operating normally. Most reports come in between roughly 2,000 and 60,000 miles, frequently at speeds under 10 mph.

   Recall 05V3790003 related service bulletins

   What to check: Ask whether recall 05V379000 was performed and whether the wheel speed sensors and EBCM ground were serviced. Drive the truck slowly over bumps and brake gently to a stop to see whether the pedal pulses or the ABS engages unexpectedly.

   2 excerpts from owner complaints in NHTSA records

   “I have a 2002 Gmc Sierra with ABS which falsely activates at slow speeds. Many friends have had similar complaints, one of which connected me to you folks. The situation is as known in pe05020. The fix is temporary and typically lasts 9 - 12 months.”

   NHTSA complaint #10132965, filed 2005-08, 48,000 miles

   “Anti lock brakes would activate for for no reason at all once and a while at slow speeds condition got worse until I could not stop for a stop sign and also hit a curb I had to remove the fuse to disable the anti lock brakes to avoid a bad crash.”

   NHTSA complaint #10129301, filed 2005-07, 51,000 miles
2. 2
   Brakes

   Rusted brake lines and rotors

   • 73 complaints (29%)
   • median 70,000 mi at 10.0 yrs old (67 state mileage)
   • 4 mention a crash, fire or injury
   • owner-quoted repair $850 (median of 9 quotes)
   • filed 2004–2016

   Complaints describe metal brake lines corroding through above the rear axle or along the frame, leading to a pedal that sinks to the floor and loss of braking. Owners also report rear rotors that rust or score early, causing a pulsating pedal, longer stopping distances or failed state safety inspections, with the front brakes following. Dealers frequently attributed the rotor condition to climate or normal wear, and in some cases resurfaced or replaced rotors and pads without covering the cost. Rotors are often reported between about 15,000 and 35,000 miles and mostly in northern or eastern states; line failures tend to appear from about 80,000 miles upward.

   1 related service bulletin

   What to check: Have the brake lines under the driver's side and above the rear axle inspected for rust, and check rotor condition and pedal feel. Ask whether the lines or rotors have been replaced and when.

   2 excerpts from owner complaints in NHTSA records

   “While driving my 2002 Gmc Sierra I depressed the brake peddle to stop at a red light. The brake peddle went all the way to the floor and the truck continued forward. I swerved off the road to miss hitting the car in front of me. After inspecting under the truck I noticed one of my brake lines had rusted completely threw and the rest didn't look much better.”

   NHTSA complaint #10477417, filed 2012-09, 99,000 miles

   “I stepped on the brake pedal to shift the truck from out of park and the pedal went to the floor. I got out of the truck and found a puddle of fluid in the area in front of the drivers side rear tire. It appeared as though the brake line going to the back brakes ruptured in the area behind the gas tank.”

   NHTSA complaint #10486266, filed 2012-11, 125,000 miles
3. 3
   Brakes

   Parking brake will not hold the truck

   • 17 complaints (7%)
   • median 30,000 mi at 4.1 yrs old (16 state mileage)
   • filed 2003–2012

   Owners report the parking brake failing to hold on an incline or dragging and grinding while driving, with rear shoes worn away prematurely. Some say the truck failed state inspection because of it, and others note that recalls 05V161000 or the dealer said the VIN was not covered even though the symptoms matched. In one case the dealer recommended replacing the rear hubs because of the dragging bands. Reported from about 10,000 to 54,000 miles, sometimes within the first year of ownership.

   Recall 05V161000

   What to check: Park on a slope and set the parking brake to confirm it holds, and listen for grinding while rolling slowly. Ask whether recall 05V161000 applies to the VIN.

   2 excerpts from owner complaints in NHTSA records

   “Dt: the contact states there is NHTSA recall campaign 05v161000 concerning the parking brake. This vehicle has the same problems as indicated in the recall, but it is not included in the recall due to VIN. Updated 1/11/2006 - the vehicle's parking brake failed at approximately 30000 miles.”

   NHTSA complaint #10145126, filed 2005-12, 30,000 miles

   “- the contact owns a 2002 chevrolet Sierra 1500 that he purchased in december 2001. Six months after the date of purchase the emergency brake did not work. He took the truck to the dealer , and they told him there was no recall on the truck because of the VIN he gave them. His friend has the same truck, but his VIN fell under this recall. Also called the manufacturer, and they informed him that this vehicle didnot fall within the recall for the emergency brake due to tne VIN. …”

   NHTSA complaint #10181279, filed 2007-01, 10,000 miles
4. 4
   Engine cooling

   Engine stalls or cuts out while driving

   • 10 complaints (4%)
   • median 52,400 mi at 5.9 yrs old (6 state mileage, few)
   • filed 2002–2011

   Complaints describe the engine quitting without warning at various speeds, sometimes with loss of power steering and power assist for braking, and occasional difficulty restarting. Owners mention repeated fuel pump and sending unit replacements, crankshaft sensor replacement and multiple dealer visits where no fault codes could be found. Some report the stalling became more frequent over time, with fewer miles between events. Typically reported between roughly 40,000 and 55,000 miles, sometimes at idle shortly after purchase.

   2 related service bulletins

   What to check: Ask about any history of stalling, fuel pump or crankshaft sensor replacement, and check the service history for repeat fault-code visits. A test drive that includes idle and steady-speed running is worth doing.

   2 excerpts from owner complaints in NHTSA records

   “Dt vehicle stalls and does not restart, it could be sitting an hour or day and it will not restart. Dealer has had the vehicle, and they could not pin point the problem. Vehicle did not capture any codes, and it stalled while actually driving . Used to be several miles between stalls it had longer intervals between stalls now its down to less than 100 miles between engine stalling. .”

   NHTSA complaint #10127740, filed 2005-07, 50,800 miles

   “Consumer complains of premature stalling at idle. The vehicle lacks sufficient power, it surges and at times refuses to accelerate. The transmission doesn't shift down properly out of 4th gear and the air conditioning unit does not cool properly and makes whistling noises.”

   NHTSA complaint #10001480, filed 2003-01, 1,500 miles

Buying note. On this model year, brake condition is the main thing to verify: have the lines, rotors and parking brake inspected, and confirm whether the ABS recall applied and was performed. Ask for service records covering brake, fuel pump and transmission work before deciding.

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.