VehicleVerdict

2002 GMC Sierra 2500 problems

Verdict · NHTSA data

One of the years to avoid

With 164 complaints filed to NHTSA — about 2.9 times the median Sierra 2500 year — the 2002 model ranks #4 of 31 Sierra 2500 years for complaint volume. It lands on the years-to-avoid list. Reports tied to this model year include one death and 12 injuries, per the complaint records themselves.

The trouble concentrates in one system: brakes issues account for 49% of all reports (80 of 164), far ahead of transmission at 14.

164

NHTSA complaints

4

Recalls

3

Investigations

13

Crash-involved

2

Fires reported

12

Injuries

1

Deaths

NCAP overall

How does 2002 compare to other Sierra 2500 years?

See all Sierra 2500 years to avoid →

What are the most common 2002 GMC Sierra 2500 problems?

ComponentComplaintsShare
Brakes8049%
Transmission149%
Fuel System138%
Engine138%
Steering95%
Body & Structure64%
Tires & Wheels53%
Airbags42%
Suspension42%
Trailer Hitch32%
Other32%
Visibility & Wipers21%
Latches & Locks21%
Seat Belts21%
Speed Control21%
Lighting11%
Electrical System11%

Does the 2002 GMC Sierra 2500 have recalls?

4 NHTSA recall campaigns on file. Recall repairs are free at franchised dealers.

06E050000BrakesJune 6, 2006 · 6,800 units

Defect

CERTAIN FEDERAL-MOGUL NATIONAL AND CARQUEST AFTERMARKET HUB ASSEMBLIES, P/N 515058, SOLD FOR USE ON 2001-2006 GENERAL MOTORS 1500 AND 2500 4WD TRUCKS. ON THE SUBJECT HUB ASSEMBLIES, THE ABS SENSOR CORD DEPARTS FROM THE HUB ASSEMBLY AT A 90 DEGREE ANGLE. AS A RESULT, THERE IS A FIT ISSUE WITH THE BRAKE ROTOR DUST SHIELD INTERFERING WITH THE ABS SENSOR CORD. IF THE HUB ASSEMBLY IS INSTALLED DESPITE THIS INTERFERENCE, THE GAP BETWEEN THE ABS SENSOR AND THE TONE WHEEL MAY BE ALTERED. THIS MAY WEAKEN THE OUTPUT OF THE ABS SENSOR. DIMINISHED OUTPUT COULD RESULT IN AN UNWANTED ABS ACTIVATION AT LOW SPEEDS AND STOPPING DISTANCE COULD BE AFFECTED.

Consequence

IF STOPPING DISTANCE IS LIMITED, A VEHICLE CRASH COULD OCCUR.

Remedy

FEDERAL-MOGUL WILL NOTIFY ITS OWNERS AND WILL EITHER CREDIT THE CUSTOMERS ACCOUNT OR REPLACE THE UNIT. THE RECALL IS EXPECTED TO BEGIN DURING JUNE 2006. OWNERS CAN CONTACT FEDERAL-MOGUL CUSTOMER SERVICE AT 1-800-563-8507 EXT 3530.

06E043000Fuel SystemMay 19, 2006 · 88,303 units

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.

Consequence

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).

06E010000SteeringFebruary 1, 2006 · 1,360 units

Defect

CERTAIN FABTECH AFTERMARKET REPLACEMENT PITMAN ARMS, P/NOS. FTS71000 AND FTS71001, INSTALLED FOR USE ON CERTAIN 2001-2006 GM C/K 2500 PICK UP TRUCKS AND SPORT UTILITY VEHICLES. THE PIN LOCATED INSIDE THE PITMAN ARM CAN SHEAR OFF DUE TO A REVERSE BENDING FATIGUE CONDITION, RESULTING IN A TOTAL LOSS OF STEERING CONTROL.

Consequence

LOSS OF STEERING CONTROL COULD LEAD TO A VEHICLE CRASH WITH POTENTIAL INJURY OR DEATH.

Remedy

FABTECH WILL NOTIFY OWNERS AND REPLACE THE PITMAN AND IDLER ARMS FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING FEBRUARY 2006. OWNERS MAY CONTACT FABTECH AT 909-597-7800.

01V220000LightingJune 26, 2001 · 38,863 units

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.

Consequence

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.

Consumer complaints filed with NHTSA

Representative excerpts, cleaned of personal information. These are consumer statements, not verified defects.

BACKING MY TRUCK DOWN A BOAT LAUNCH TO PUT A PWC IN. AS I APPLIED THE BRAKE AT THE BOTTOM OF THE RAMP, THE PEDAL WENT TO THE FLOOR, LOSING ALL BRAKES. SINCE I WAS CLOSE TO THE WATER, BY THE TIME I GOT IT INTO FORWARD, IT WAS ALREADY OVER THE EDGE OF THE RAMP INTO THE WATER. SUBMERGED UP TO THE…

Complaint filed with NHTSA · Brakes · July 5, 2014 · crash

LIMITED SLIP DIFFERENTIAL CAUSING LOSS OF CONTROL ON ICY ROADS. I RECENTLY LOST CONTROL OF MY TRUCK WHILE DRIVING ABOUT 45MPH ON AN ICY HIGHWAY IN BOULDER, CO. BECAUSE THE LOSS WAS SO INSTANTANEOUS RESULTING IN THE TRUCK SPINNING 90 DEGREES TO THE DIRECTION OF TRAVEL, I QUESTION IF THE LIMITED SLIP…

Complaint filed with NHTSA · Transmission · December 23, 2009 · crash

THE TRUCK HAS SEVERAL BROKEN EXHAUST MANIFOLD STUDS THAT ARE COMPLETELY RUSTED OUT CAUSING FAILURE OF CORRECT EMISSION CONTROLS THROUGH THE CATALYTIC CONVERTER, AND OUT OF THE HEADERS INSTEAD. THIS IS ENVIRONMENTALLY UNFRIENDLY, AND IS REALLY ANNOYING AS THE EXHAUST LEAKS FROM UNDER THE HOOD DUE TO…

Complaint filed with NHTSA · Engine · November 1, 2012

TL* THE CONTACT OWNS A 2002 GMC 2500 HD DIESEL. THE CONTACT STATED THAT THE VEHICLE EXHIBITED AN UNKNOWN INTERNAL FUEL LEAK THAT WOULD OVERFLOW INTO THE CRANK CASE. THE MANUFACTURER WAS CONTACTED BUT WOULD NOT PROVIDE ANY ASSISTANCE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND THE CURRENT…

Complaint filed with NHTSA · Fuel System · July 15, 2010

STARTED MY VEHICLE SO COULD MOVE IT IN FRONT OF MY GARAGE. WHEN I TRIED TO TURN THE STEERING WHEEL WOULDN'T MOVE AND I HAD VERY LIMITED BRAKING POWER. IT TOOK AN EXCEPTIONAL AMOUNT OF PRESSURE ON THE BRAKE PEDAL JUST TO STOP THE VEHICLE AT A VERY LOW SPEED. THANKFULLY NO ONE WAS HURT AND NO…

Complaint filed with NHTSA · Steering · May 20, 2008

2002 GMC Sierra 2500 — common questions

Is the 2002 GMC Sierra 2500 reliable?

NHTSA data argues against it: 164 complaints put the 2002 model at #4 of 31 Sierra 2500 years. It is one of the Sierra 2500 years to avoid.

What are the most common 2002 Sierra 2500 problems?

According to NHTSA complaint data, the leading problem areas are brakes (80 complaints), transmission (14 complaints), fuel system (13 complaints).

Does the 2002 GMC Sierra 2500 have recalls?

Yes — NHTSA lists 4 recall campaigns affecting the 2002 GMC Sierra 2500. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

Is the 2002 GMC Sierra 2500 under NHTSA investigation?

NHTSA opened 3 investigations into this model year; all are now closed.

Which GMC Sierra 2500 years should you avoid?

Based on complaint rates and open investigations, the Sierra 2500 years to avoid are 2003, 2004, 2001, 2002, 2005, 2024, 2020, 2015, 2007, 2011, 2008, 2013, 2012, 2014, 2009, 2010. The cleanest record among Sierra 2500 years belongs to 1994.

Related

Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.

Compiled by Sharon Ben-Moshe, Founder.