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2002 Chevrolet Silverado 2500

Owner reports · Recalls · Investigations

More warning signs than most Silverado 2500 years

Owner complaints for the 2002 Chevrolet Silverado 2500 are substantially higher than the model-year median of 81.

About this comparison →

When problems were reported

Mileage at the reported incident

307 reports with mileage · 44 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Service Brakes, Hydraulic. Review the 117 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes. Review the 88 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine And Engine Cooling. Review the 43 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

21 crash reports6 fire reports7 injury reports

What owners actually said

351 reports
114,000 miles · May 18, 2011
Engine And Engine CoolingFuel System, Diesel

I HAVE A 2002 CHEVROLET SILVERADO 2500HD LT EXT. CAB LB7 DURAMAX 5 SPEED ALLISON TRANSMISSION, IT HAS 114000 MILES ON IT. THIS TRUCK HAS BEEN SERVICED AS DIRECTED SINCE NEW. THE TRUCK STARTED USING LOTS OF FUEL, AT AN IDLE IT SERGED BETWEEN 700 & 900 RPM'S, AND OIL STARTED BLOWING OUT THE BLOWBY TUBE. I HAVE JUST FOUND OUT THAT…

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I HAVE A 2002 CHEVROLET SILVERADO 2500HD LT EXT. CAB LB7 DURAMAX 5 SPEED ALLISON TRANSMISSION, IT HAS 114000 MILES ON IT. THIS TRUCK HAS BEEN SERVICED AS DIRECTED SINCE NEW. THE TRUCK STARTED USING LOTS OF FUEL, AT AN IDLE IT SERGED BETWEEN 700 & 900 RPM'S, AND OIL STARTED BLOWING OUT THE BLOWBY TUBE. I HAVE JUST FOUND OUT THAT 3 FUEL INJECTORS ARE LEAKING FUEL, WITH A POSSIBLE HEAD GASKET LEAK,FILLING MY CRANKCASE WITH DIESEL, CAUSING OIL TO BLOW OUT ALL OVER THE TRUCK, ROAD AND WHATEVER ELSE IT CAN LAND ON. WHILE INVESTIGATING WHAT TO DO, TO FIX THE TRUCK I'VE FOUND 3 OTHER PEOPLE I KNOW THAT HAVE DURAMAX'S, AND THEY ARE GOING THROUGH THE SAME PROBLEMS. IT'S GOING TO TAKE ME A YEAR TO SAVE THE MONEY I NEED TO FIX THIS TRUCK. I'M EVEN GOING TO DO THE WORK MYSELF. IN MY OPINION GM SHOULD BE ASHAMED. THEY SHOULD AT LEASED PAY FOR THE PARTS. THE CHEAPEST INJECTORS I'VE FOUND ARE $225.00 APIECE WITH A $125.00 CORE CHARGE. IT'S RECOMENDED THAT ALL 8 INJECTORS BE REPLACED AT ONCE. I'VE ALSO BEEN TOLD THESE ENGINES HAVE DEFECTIVE HEAD GASKETS. THAT WILL COST ANOTHER $600.00 FOR PARTS, AND $110.00 FOR SPECIAL TOOLS I NEED TO DO THE JOB. WHEN I FORKED OVER THE $40,000 CASH INHERITINCE MONEY TO BUY THIS TRUCK, I DIDN'T SIGNUP FOR THIS. *TR

NHTSA ODI #10401382

101,112 miles · May 17, 2011
Engine And Engine Cooling

I OWN A 2002 CHEVROLET 2500 HD WITH THE 8.1 (8100 VORTEC) ENGINE. I HAD BEGAN HAVING PROBLEMS WITH THE ENGINE STALLING WHILE DRIVING PERIODICALLY. IT BECAME A FREQUENT PROBLEM. I HAD THE VEHICLE SCANNED AT A LOCAL AUTO PARTS STORE WITH NO FAULT CODES SHOWING. I LEARNED THE CRANKSHAFT POSITION SENSOR WAS AT FAULT BY DOING SOME ON…

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I OWN A 2002 CHEVROLET 2500 HD WITH THE 8.1 (8100 VORTEC) ENGINE. I HAD BEGAN HAVING PROBLEMS WITH THE ENGINE STALLING WHILE DRIVING PERIODICALLY. IT BECAME A FREQUENT PROBLEM. I HAD THE VEHICLE SCANNED AT A LOCAL AUTO PARTS STORE WITH NO FAULT CODES SHOWING. I LEARNED THE CRANKSHAFT POSITION SENSOR WAS AT FAULT BY DOING SOME ONLINE RESEARCH. I ALSO LEARNED THE SAME ENGINE HAD A RECALL IN 2001 AND NOT 2002 THE FACT THE VEHICLE STALLS DURING OPERATION IS A SERIOUS HAZARD . CHEVROLET NEEDS TO TAKE RESPONSIBILITY FOR THIS AND RECALL THESE VEHICLES . I CHANGED MY OWN , BUT CHEVROLET NEEDS TO FIX THIS FAST BEFORE SOMEONE DIES IF THEY HAVEN'T ALREADY ! *TR

NHTSA ODI #10401275

219,500 miles · May 12, 2011
Service Brakes, HydraulicFire

I HAVE A 2002 CHEVY SILVERADO 2500HD NEARLY CAUGHT FIRE YESTERDAY. A LEAK DEVELOPED IN THE POWER BRAKE BOOSTER/HYDRO-BOOST SYSTEM AND POWER STEERING FLUID WAS LEAKING ONTO MY HOT EXHAUST MANIFOLD. SMOKE WAS POURING FROM UNDER MY HOOD. I SUSPECT A SMALL FIRE BECAUSE OF THE AMOUNT OF SMOKE. BY THE TIME I PULLED OFF THE ROAD AN…

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I HAVE A 2002 CHEVY SILVERADO 2500HD NEARLY CAUGHT FIRE YESTERDAY. A LEAK DEVELOPED IN THE POWER BRAKE BOOSTER/HYDRO-BOOST SYSTEM AND POWER STEERING FLUID WAS LEAKING ONTO MY HOT EXHAUST MANIFOLD. SMOKE WAS POURING FROM UNDER MY HOOD. I SUSPECT A SMALL FIRE BECAUSE OF THE AMOUNT OF SMOKE. BY THE TIME I PULLED OFF THE ROAD AND OPENED THE HOOD ALL I SAW WAS SMOKE FROM SOMETHING LEAKING ON THE MANIFOLD. I GOT ONLINE AND FOUND THIS RECALL INFORMATION FOR 2004-2005 CHEVY TRUCKS BUT NOT 2002. I WANTED TO INFORM YOU THAT THERE MAY BE A NEED TO RECALL 2002 SILVERADO TRUCKS AS WELL. RESEARCHING DIESELPLACE.COM AND DIESELPAGE.COM THIS PROBLEM IS COMMON AND WIDESPREAD. ---------------------------------------------------------------------------------- MARCH 2005 DEAR CHEVROLET CUSTOMER: THIS NOTICE IS SENT TO YOU IN ACCORDANCE WITH THE REQUIREMENTS OF THE NATIONAL TRAFFIC AND MOTOR VEHICLE SAFETY ACT. REASON FOR THIS RECALL: GENERAL MOTORS HAS DECIDED THAT A DEFECT, WHICH RELATES TO MOTOR VEHICLE SAFETY, EXISTS IN CERTAIN 2004 MODEL YEAR CHEVROLET KODIAK AND CERTAIN 2004 AND 2005 MODEL YEAR CHEVROLET AVALANCHE, EXPRESS, SILVERADO, AND SUBURBAN VEHICLES. ON SOME OF THESE VEHICLES, THE HYDRAULIC BRAKE BOOSTER'S PRESSURE ACCUMULATOR MAY CRACK AND/OR SEPARATE FROM THE HYDRO-BOOST ASSEMBLY DURING NORMAL VEHICLE OPERATING CONDITIONS. IF A SEPARATION WERE TO OCCUR AND THE HOOD OF THE VEHICLE WERE OPEN, FRAGMENTS FROM THE ACCUMULATOR COULD CAUSE INJURY TO PEOPLE IN THE IMMEDIATE AREA. IN ADDITION, THE PRESENCE OF THIS CRACK OR FRACTURED SURFACE COULD ALLOW THE HYDRAULIC FLUID TO LEAK FROM THE ACCUMULATOR CIRCUIT OF THE BOOSTER ASSEMBLY. THE LOSS OF FLUID WOULD CAUSE INCREASED STEERING AND BRAKING EFFORT. WHAT WILL BE DONE: YOUR CHEVROLET DEALER WILL INSPECT THE HYDRAULIC BRAKE BOOSTER, AND REPLACE IT IF NECESSARY. THIS SERVICE WILL BE PERFORMED FOR YOU AT NO CHARGE. *TR

NHTSA ODI #10400630

55,000 miles · May 5, 2011
Engine And Engine Cooling

2002 2500HD CHEVY SILVERADO STALLING FOR THE LAST 6 MONTHS RANDOMLY. TAKEN TO HAVE FIXED CANNOT IDENTIFY THE PROBLEM WITH COMPUTER SCAN. TRUCK STALLING ON THE HIGHWAY MANY TIMES. ONCE TRUCK STALLS, TURN OFF KEY, LET SET FOR 10 -15 SECONDS, RESTART. I GUESS THE SYSTEM RESETS ITSELF. THIS IS NOT SAFE. *TR

NHTSA ODI #10399200

79,000 miles · Apr 4, 2011
Service Brakes, Hydraulic

BRAKE LINES RUPTURE AND BRAKES FAIL. I'VE HAD THIS HAPPEN THREE TIMES AND IN RESEARCHING THIS PROBLEM HAVE SEEN ON-LINE THAT IT'S QUITE COMMON WITH MY BRAND OF TRUCK. *TR

NHTSA ODI #10394142

70,887 miles · Mar 27, 2011
Engine And Engine Cooling

2002 2500HD SILVERADO WITH 8.1L GAS MOTOR STALLING RANDOMLY FOR TWO MONTHS NOW, AT LEAST 3 TIMES A WEEK. TOOK IT INTO THE DEALER AND CRANKSHAFT POSITION SENSOR WAS AT FAULT, WHICH THE DEALER TOLD ME THE 2001 8.1L HAS OPEN RECALL BUT NOT ON 2002!! LAST TIME I DROVE THE TRUCK I WAS NEARLY T-BONED DUE TO THE TRUCK DYING IN INTERS…

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2002 2500HD SILVERADO WITH 8.1L GAS MOTOR STALLING RANDOMLY FOR TWO MONTHS NOW, AT LEAST 3 TIMES A WEEK. TOOK IT INTO THE DEALER AND CRANKSHAFT POSITION SENSOR WAS AT FAULT, WHICH THE DEALER TOLD ME THE 2001 8.1L HAS OPEN RECALL BUT NOT ON 2002!! LAST TIME I DROVE THE TRUCK I WAS NEARLY T-BONED DUE TO THE TRUCK DYING IN INTERSECTION. PLEASE EVERYONE WHO HAS HAD THIS PROBLEM REPORT IT HERE! WE NEED A RECALL ON THIS CPS BEFORE SOMEONE DIES! I HAD DEALERSHIP FIX IT TO THE TUNE OF $400!!!!! CHEVY NEEDS TO OWN THIS PROBLEM! *TR

NHTSA ODI #10392985

72,000 miles · Mar 23, 2011
Service Brakes, Hydraulic

HYDRAULIC BRAKE LINE GOING TO REAR OF TRUCK FAILED DUE TO HEAVY EXTERIOR CORROSION. TRUCK IS A 3/4 TON CREW CAB WITH AN EIGHT FOOT BED. THE POINT OF FAILURE WAS NEAR WHERE LINE CROSSES TO TOP OF FRAME NEAR A LOOMED WIRE HARNESS APPROXIMATELY UNDER REAR DOOR OF CAB. ALL BRAKE LINES ON THE TRUCK ARE HEAVILY CORRODED. *TR

NHTSA ODI #10392587

150,000 miles · Mar 22, 2011
Fuel System, Gasoline

WE HAVE A 2500 HD ALSO WITH FAILED INJECTORS. WE WERE NOT INJURED NOR KILLED. HOWEVER, OIL AND DIESEL BLEW OUT ON ROADWAY AND ON THE ENGINE OF TRUCK. I DO NOT KNOW IF THIS CAUSED AN ACCIDENT WITH THE VEHICLE BEHIND ME OR NOT. HOW MANY ACCIDENTS COULD HAVE HAPPENED AND NO ONE REALIZED IT WAS FROM THE OIL OF OUR TRUCK. FURTHER …

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WE HAVE A 2500 HD ALSO WITH FAILED INJECTORS. WE WERE NOT INJURED NOR KILLED. HOWEVER, OIL AND DIESEL BLEW OUT ON ROADWAY AND ON THE ENGINE OF TRUCK. I DO NOT KNOW IF THIS CAUSED AN ACCIDENT WITH THE VEHICLE BEHIND ME OR NOT. HOW MANY ACCIDENTS COULD HAVE HAPPENED AND NO ONE REALIZED IT WAS FROM THE OIL OF OUR TRUCK. FURTHER MORE CHEVY KNOWS THIS IS A PROBLEM. SO HOW MANY PEOPLE HAVE TO GET HURT OR DIE BEFORE THEY TAKE CARE OF THE PROBLEM. OF EVERYONE I HAVE TALKED TO ONLY ONE PERSON WAS UNDER WARRANTY AND THEY MADE IT BY 14 DAYS. CHEVY HAS A PROBLEM AND NEEDS TO FIX IT, AND NOT WITH AN EXTENDED WARRANTY. THIS IS MY FIRST CHEVY AND WILL BE MY LAST. MAYBE THAT IS WHY CHEVY NEEDED BAIL OUT MONEY

NHTSA ODI #10393218

114,539 miles · Mar 7, 2011
Service Brakes, Hydraulic

2002 CHEVROLET SILVERADO 2500HD 4X4 HAD COMPLETE BRAKE FAILURE ON 3/7/2011. IT APPEARS ALL BRAKE LINES ARE SEVERALLY CORRODED AND LEAKING IN MULTIPLE LOCATIONS. TRUCK IS USED FOR PERSONAL USE AND NOT COMMERCIAL. IT DOES NOT PLOW SNOW AND WE LIVE IN ZIP CODE 20197. THE INCIDENT LUCKILY HAPPENED IN THE DRIVE WAY AND THERE WA…

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2002 CHEVROLET SILVERADO 2500HD 4X4 HAD COMPLETE BRAKE FAILURE ON 3/7/2011. IT APPEARS ALL BRAKE LINES ARE SEVERALLY CORRODED AND LEAKING IN MULTIPLE LOCATIONS. TRUCK IS USED FOR PERSONAL USE AND NOT COMMERCIAL. IT DOES NOT PLOW SNOW AND WE LIVE IN ZIP CODE 20197. THE INCIDENT LUCKILY HAPPENED IN THE DRIVE WAY AND THERE WAS NOT AN ACCIDENT. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI #10386775

70,000 miles · Mar 3, 2011
Engine And Engine Cooling

EXHAUST MANIFOLD BOLTS ON 2002 CHEVROLET 2500 HD 6.0 L V8 ARE BROKEN AT THE BACK BOLT ON THE DRIVERS SIDE. THE PASSANGER SIDE EXHAUST MANIFOLD IS CRACKED BETWEEN THE 3RD AND 4TH BOLT FROM THE FRONT. I REPLACED THE BOLTS ON THE DRIVER SIDE, EXCEPT FOR THE BACK ONE THAT IS SHEARED OFF FLUSH WITH THE CYLINDER HEAD. THE ONLY WAY TO …

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EXHAUST MANIFOLD BOLTS ON 2002 CHEVROLET 2500 HD 6.0 L V8 ARE BROKEN AT THE BACK BOLT ON THE DRIVERS SIDE. THE PASSANGER SIDE EXHAUST MANIFOLD IS CRACKED BETWEEN THE 3RD AND 4TH BOLT FROM THE FRONT. I REPLACED THE BOLTS ON THE DRIVER SIDE, EXCEPT FOR THE BACK ONE THAT IS SHEARED OFF FLUSH WITH THE CYLINDER HEAD. THE ONLY WAY TO GET THIS PARTICULAR BOLT OUT IS TO REMOVE THE CYLINDER HEAD FROM THE ENGINE SO THAT A MACHINE SHOP CAN DRILL OUT THE OFFENDING BOLT. THE REPLACEMENT BOLTS THAT I PURCHASED FROM THE GM DEALER WERE A MUCH STURDIER BOLT THAT HAD A MUCH LARGER HEAD ON THE BOLT. TO ME THIS INDICATES KNOWLEDGE THAT THERE IS A PROBLEM AND THAT GM IS AWARE OF IT. THIS WILL MOST CERTAINLY LEAD TO AN EXHAUST LEAK THAT WILL CAUSE THE CHECK ENGINE LIGHT TO COME ON. A VEHICLE WITH THE CHECK ENGINE LIGHT ON CANNOT PASS A FIELD EMISSIONS TEST AND WILL RESULT IN A REVOCATION OF THE VEHICLES REGISTRATION UNTIL THE PROBLEM IS CORRECTED. THIS IS NOW A SERIOUS PROBLEM THAT IS VERY EXPENSIVE TO REPAIR. GM SHOULD BE HELD ACCOUNTABLE FOR THE POSSIBLE EPA VIOLATIONS THAT THIS WELL DOCUMENTED ISSUE IS NOW CAUSING. THIS VEHICLE ONLY HAS 70,000 MILES ON IT, VERY LOW FOR A 2002.

NHTSA ODI #10386262

Official recalls

1

01V220000 · Interior Lighting

Jun 26, 2001

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 & remedy

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.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

4

EA07013 · Trailer Hitch Receiver Failure

Opened Sep 14, 2007 · Closed Sep 12, 2008

Status: closed (inferred from source dates) · Trailer Hitches

COMPLAINT REPORTS ALLEGE POOR WELD QUALITY AND/OR BENDING OF THE SUBJECT VEHICLE ORIGINAL EQUIPMENT TRAILER HITCH RECEIVER.THE AGENCY'S INVESTIGATION INCLUDED ANALYSIS OF MANUFACTURER AND AGENCY INCIDENT REPORTS, REVIEW OF POLICE REPORTS, ANALYSIS OF THE AGENCY'S FATAL ANALYSIS REPORTING SYSTEM, A VEHICLE OWNER SURVEY, INSPECTION OF TOW VEHICLES/HITCHES AND ANALYSIS OF FAILED PARTS.INCIDENTS OF WELD FAILURE WERE RARE AND ASSOCIATED WITH VERY LOW-SPEED DRIVING (TURNING, BACKING AND SUDDEN STOPPING).INCIDENTS OF BENDING WERE ASSOCIATED WITH IMPROPER TRAILER HITCH ADJUSTMENT OR OVERLOADING. A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL MONITOR THIS ISSUE AND RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE DOCUMENT SEARCH FILE FOR ADDITION INFORMATION.

PE07025 · Trailer Hitch Receiver Failure

Opened May 14, 2007 · Closed Sep 14, 2007

Status: closed (inferred from source dates) · Trailer Hitches

GM PROVIDED ADDITIONAL DATA REGARDING ALLEGATIONS OF FAILURE OF THE TRAILER HITCH.ODI REVIEWED THAT AS WELL AS OTHER DATA PROVIDED BY PEER MANUFACTURERS.BASED ON OUR REVIEW, ODI FINDS THE NEED TO FURTHER INVESTIGATE THIS ISSUE.THIS PRELIMINARY EVALUATION IS UPGRADED TO AN ENGINEERING ANALYSIS (EA07-013) FOR FURTHER ASSESSMENT AND STUDY OF THIS ISSUE.

EA04012 · Hydraulic Pump Failres

Opened Apr 30, 2004 · Closed Feb 28, 2005

Status: closed (inferred from source dates) · Service Brakes, Hydraulic:power Assist; Steering:hydraulic Power Assist System

GM IS CONDUCTING A RECALL ON ALL SUBJECT VEHICLES BUILD BETWEEN MAY 1999 AND OCTOBER 14, 1999.SIGNIFICANT CHANGES WERE INCORPORATED INTO PRODUCTION IN EARLY OCTOBER 1999, AND VEHICLES BUILT AFTER THAT DATE HAVE LOWER WARRANTY FAILURE RATES.THE COMPLAINT AND WARRANTY DATA APPEAR TO SUPPORT THE EFFECTIVENESS OF THESE CHANGES. GM MADE ADDITIONAL CHANGES IN NOVEMBER 1999, FEBRUARY 2000, MAY 2001, AND FEBRUARY 2004.ODI WILL CONTINUE TO MONITOR THIS PROBLEM AND WILL TAKE FURTHER ACTION, IF WARRANTED, IN THE FUTURE.FOR FURTHER TECHNICAL DETAILS SEE THE ATTACHED ENGINEERING ANALYSIS REPORT.

Additional source detail variants (2)

Service Brakes, Hydraulic:power Assist

GM IS CONDUCTING A RECALL ON ALL SUBJECT VEHICLES BUILD BETWEEN MAY 1999 AND OCTOBER 14, 1999.SIGNIFICANT CHANGES WERE INCORPORATED INTO PRODUCTION IN EARLY OCTOBER 1999, AND VEHICLES BUILT AFTER THAT DATE HAVE LOWER WARRANTY FAILURE RATES.THE COMPLAINT AND WARRANTY DATA APPEAR TO SUPPORT THE EFFECTIVENESS OF THESE CHANGES. GM MADE ADDITIONAL CHANGES IN NOVEMBER 1999, FEBRUARY 2000, MAY 2001, AND FEBRUARY 2004.ODI WILL CONTINUE TO MONITOR THIS PROBLEM AND WILL TAKE FURTHER ACTION, IF WARRANTED, IN THE FUTURE.FOR FURTHER TECHNICAL DETAILS SEE THE ATTACHED ENGINEERING ANALYSIS REPORT.

Steering:hydraulic Power Assist System

GM IS CONDUCTING A RECALL ON ALL SUBJECT VEHICLES BUILD BETWEEN MAY 1999 AND OCTOBER 14, 1999.SIGNIFICANT CHANGES WERE INCORPORATED INTO PRODUCTION IN EARLY OCTOBER 1999, AND VEHICLES BUILT AFTER THAT DATE HAVE LOWER WARRANTY FAILURE RATES.THE COMPLAINT AND WARRANTY DATA APPEAR TO SUPPORT THE EFFECTIVENESS OF THESE CHANGES. GM MADE ADDITIONAL CHANGES IN NOVEMBER 1999, FEBRUARY 2000, MAY 2001, AND FEBRUARY 2004.ODI WILL CONTINUE TO MONITOR THIS PROBLEM AND WILL TAKE FURTHER ACTION, IF WARRANTED, IN THE FUTURE.FOR FURTHER TECHNICAL DETAILS SEE THE ATTACHED ENGINEERING ANALYSIS REPORT.

PE04004 · Hydraulic Pump Shaft Failures

Opened Jan 8, 2004 · Closed Apr 30, 2004

Status: closed (inferred from source dates) · Service Brakes, Hydraulic; Service Brakes, Hydraulic:power Assist; Service Brakes, Hydraulic:power Assist:hydraulic; Steering:hydraulic Power Assist System; Steering:hydraulic Power Assist:pump

THE PRELIMINARY EVAULATION IS BEING UPGRADED.DURING THE EA ODI WILL LIMITITS INVESTIGATION TO ONLY THOSE VEHICLES EQUIPPED WITH A HYDRO-BOOST SYSTEM, WHICH PROVIDES POWER ASSIST TO THE BRAKING AND STEERING SYTEMS.VACCUUM BRAKE BOOSTER VEHICLES ARE EXCLUDED.ODI HASEXPANDED THE SCOPE OF THE EA TO INCLUDE MODEL YEARS2003 AND 2004, ASDURING THE PE, ODI LEARNED THAT THE HYDROBOAST PUMPS WERE MODIFIED IN FEBRAURY 2004.THEREFORE,ODI HAS EXPANDED THE SCOPE TO INCLUDE THE ADDITIONAL MODEL YEARS.ODI'S IS CONCERNED BECAUSE THISISA SUDDEN FAILURE THAT AFFECTS TWO CRITICAL SYSTEMS OF THE VEHICLE, BRAKES AND STEERING, AT THE SAME TIME.THE ABILITY OF THE OPERATOR TO HANDLE THE DUAL FAILURES IS A CONCERN. FURTHER, THESE VEHICLES TEND TO BE WORK VEHICLES, WITH SOME OVER 10,000 POUNDS GVWR AND MANY EQUIPPED TO PULL LARGE TRAILERS.DUAL FAILURES OF HEAVILY LOADED VEHICLES AND VEHICLES PULLING TRAILERS FURTHER INCREASES THE SAFETY RISK.ODI PLANS TO CONDUCT TESTING TO QUANTIFY THE BRAKING AND STEERING PERFORMANCE DEGRADATION AND THE IMPACT ON SAFE VEHICLE CONTROL, WHEN A HYDROBOAST PUMP FAILS.

Additional source detail variants (5)

Service Brakes, Hydraulic

THE PRELIMINARY EVAULATION IS BEING UPGRADED.DURING THE EA ODI WILL LIMITITS INVESTIGATION TO ONLY THOSE VEHICLES EQUIPPED WITH A HYDRO-BOOST SYSTEM, WHICH PROVIDES POWER ASSIST TO THE BRAKING AND STEERING SYTEMS.VACCUUM BRAKE BOOSTER VEHICLES ARE EXCLUDED.ODI HASEXPANDED THE SCOPE OF THE EA TO INCLUDE MODEL YEARS2003 AND 2004, ASDURING THE PE, ODI LEARNED THAT THE HYDROBOAST PUMPS WERE MODIFIED IN FEBRAURY 2004.THEREFORE,ODI HAS EXPANDED THE SCOPE TO INCLUDE THE ADDITIONAL MODEL YEARS.ODI'S IS CONCERNED BECAUSE THISISA SUDDEN FAILURE THAT AFFECTS TWO CRITICAL SYSTEMS OF THE VEHICLE, BRAKES AND STEERING, AT THE SAME TIME.THE ABILITY OF THE OPERATOR TO HANDLE THE DUAL FAILURES IS A CONCERN. FURTHER, THESE VEHICLES TEND TO BE WORK VEHICLES, WITH SOME OVER 10,000 POUNDS GVWR AND MANY EQUIPPED TO PULL LARGE TRAILERS.DUAL FAILURES OF HEAVILY LOADED VEHICLES AND VEHICLES PULLING TRAILERS FURTHER INCREASES THE SAFETY RISK.ODI PLANS TO CONDUCT TESTING TO QUANTIFY THE BRAKING AND STEERING PERFORMANCE DEGRADATION AND THE IMPACT ON SAFE VEHICLE CONTROL, WHEN A HYDROBOAST PUMP FAILS.

Service Brakes, Hydraulic:power Assist

THE PRELIMINARY EVAULATION IS BEING UPGRADED.DURING THE EA ODI WILL LIMITITS INVESTIGATION TO ONLY THOSE VEHICLES EQUIPPED WITH A HYDRO-BOOST SYSTEM, WHICH PROVIDES POWER ASSIST TO THE BRAKING AND STEERING SYTEMS.VACCUUM BRAKE BOOSTER VEHICLES ARE EXCLUDED.ODI HASEXPANDED THE SCOPE OF THE EA TO INCLUDE MODEL YEARS2003 AND 2004, ASDURING THE PE, ODI LEARNED THAT THE HYDROBOAST PUMPS WERE MODIFIED IN FEBRAURY 2004.THEREFORE,ODI HAS EXPANDED THE SCOPE TO INCLUDE THE ADDITIONAL MODEL YEARS.ODI'S IS CONCERNED BECAUSE THISISA SUDDEN FAILURE THAT AFFECTS TWO CRITICAL SYSTEMS OF THE VEHICLE, BRAKES AND STEERING, AT THE SAME TIME.THE ABILITY OF THE OPERATOR TO HANDLE THE DUAL FAILURES IS A CONCERN. FURTHER, THESE VEHICLES TEND TO BE WORK VEHICLES, WITH SOME OVER 10,000 POUNDS GVWR AND MANY EQUIPPED TO PULL LARGE TRAILERS.DUAL FAILURES OF HEAVILY LOADED VEHICLES AND VEHICLES PULLING TRAILERS FURTHER INCREASES THE SAFETY RISK.ODI PLANS TO CONDUCT TESTING TO QUANTIFY THE BRAKING AND STEERING PERFORMANCE DEGRADATION AND THE IMPACT ON SAFE VEHICLE CONTROL, WHEN A HYDROBOAST PUMP FAILS.

Service Brakes, Hydraulic:power Assist:hydraulic

THE PRELIMINARY EVAULATION IS BEING UPGRADED.DURING THE EA ODI WILL LIMITITS INVESTIGATION TO ONLY THOSE VEHICLES EQUIPPED WITH A HYDRO-BOOST SYSTEM, WHICH PROVIDES POWER ASSIST TO THE BRAKING AND STEERING SYTEMS.VACCUUM BRAKE BOOSTER VEHICLES ARE EXCLUDED.ODI HASEXPANDED THE SCOPE OF THE EA TO INCLUDE MODEL YEARS2003 AND 2004, ASDURING THE PE, ODI LEARNED THAT THE HYDROBOAST PUMPS WERE MODIFIED IN FEBRAURY 2004.THEREFORE,ODI HAS EXPANDED THE SCOPE TO INCLUDE THE ADDITIONAL MODEL YEARS.ODI'S IS CONCERNED BECAUSE THISISA SUDDEN FAILURE THAT AFFECTS TWO CRITICAL SYSTEMS OF THE VEHICLE, BRAKES AND STEERING, AT THE SAME TIME.THE ABILITY OF THE OPERATOR TO HANDLE THE DUAL FAILURES IS A CONCERN. FURTHER, THESE VEHICLES TEND TO BE WORK VEHICLES, WITH SOME OVER 10,000 POUNDS GVWR AND MANY EQUIPPED TO PULL LARGE TRAILERS.DUAL FAILURES OF HEAVILY LOADED VEHICLES AND VEHICLES PULLING TRAILERS FURTHER INCREASES THE SAFETY RISK.ODI PLANS TO CONDUCT TESTING TO QUANTIFY THE BRAKING AND STEERING PERFORMANCE DEGRADATION AND THE IMPACT ON SAFE VEHICLE CONTROL, WHEN A HYDROBOAST PUMP FAILS.

Steering:hydraulic Power Assist:pump

THE PRELIMINARY EVAULATION IS BEING UPGRADED.DURING THE EA ODI WILL LIMITITS INVESTIGATION TO ONLY THOSE VEHICLES EQUIPPED WITH A HYDRO-BOOST SYSTEM, WHICH PROVIDES POWER ASSIST TO THE BRAKING AND STEERING SYTEMS.VACCUUM BRAKE BOOSTER VEHICLES ARE EXCLUDED.ODI HASEXPANDED THE SCOPE OF THE EA TO INCLUDE MODEL YEARS2003 AND 2004, ASDURING THE PE, ODI LEARNED THAT THE HYDROBOAST PUMPS WERE MODIFIED IN FEBRAURY 2004.THEREFORE,ODI HAS EXPANDED THE SCOPE TO INCLUDE THE ADDITIONAL MODEL YEARS.ODI'S IS CONCERNED BECAUSE THISISA SUDDEN FAILURE THAT AFFECTS TWO CRITICAL SYSTEMS OF THE VEHICLE, BRAKES AND STEERING, AT THE SAME TIME.THE ABILITY OF THE OPERATOR TO HANDLE THE DUAL FAILURES IS A CONCERN. FURTHER, THESE VEHICLES TEND TO BE WORK VEHICLES, WITH SOME OVER 10,000 POUNDS GVWR AND MANY EQUIPPED TO PULL LARGE TRAILERS.DUAL FAILURES OF HEAVILY LOADED VEHICLES AND VEHICLES PULLING TRAILERS FURTHER INCREASES THE SAFETY RISK.ODI PLANS TO CONDUCT TESTING TO QUANTIFY THE BRAKING AND STEERING PERFORMANCE DEGRADATION AND THE IMPACT ON SAFE VEHICLE CONTROL, WHEN A HYDROBOAST PUMP FAILS.

Steering:hydraulic Power Assist System

THE PRELIMINARY EVAULATION IS BEING UPGRADED.DURING THE EA ODI WILL LIMITITS INVESTIGATION TO ONLY THOSE VEHICLES EQUIPPED WITH A HYDRO-BOOST SYSTEM, WHICH PROVIDES POWER ASSIST TO THE BRAKING AND STEERING SYTEMS.VACCUUM BRAKE BOOSTER VEHICLES ARE EXCLUDED.ODI HASEXPANDED THE SCOPE OF THE EA TO INCLUDE MODEL YEARS2003 AND 2004, ASDURING THE PE, ODI LEARNED THAT THE HYDROBOAST PUMPS WERE MODIFIED IN FEBRAURY 2004.THEREFORE,ODI HAS EXPANDED THE SCOPE TO INCLUDE THE ADDITIONAL MODEL YEARS.ODI'S IS CONCERNED BECAUSE THISISA SUDDEN FAILURE THAT AFFECTS TWO CRITICAL SYSTEMS OF THE VEHICLE, BRAKES AND STEERING, AT THE SAME TIME.THE ABILITY OF THE OPERATOR TO HANDLE THE DUAL FAILURES IS A CONCERN. FURTHER, THESE VEHICLES TEND TO BE WORK VEHICLES, WITH SOME OVER 10,000 POUNDS GVWR AND MANY EQUIPPED TO PULL LARGE TRAILERS.DUAL FAILURES OF HEAVILY LOADED VEHICLES AND VEHICLES PULLING TRAILERS FURTHER INCREASES THE SAFETY RISK.ODI PLANS TO CONDUCT TESTING TO QUANTIFY THE BRAKING AND STEERING PERFORMANCE DEGRADATION AND THE IMPACT ON SAFE VEHICLE CONTROL, WHEN A HYDROBOAST PUMP FAILS.