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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
28,322 miles · Jan 6, 2010
Service Brakes, Hydraulic

I AM THE ORIGINAL OWNER OF A 2002 CHEVROLET SILVERADO 2500HD PICKUP TRUCK. ON 12/11/09 WHILE DRIVING THE TRUCK, I APPLIED THE BRAKES AND THE PEDAL WENT COMPLETELY TO THE FLOOR, LEAVING ME WITH NO BRAKES. FORTUNATELY, I WAS GOING VERY SLOW AT THE TIME AND WAS ABLE TO ROLL TO A SLOW STOP WITH NO DAMAGE OR INJURY. I FOUND THAT MY B…

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I AM THE ORIGINAL OWNER OF A 2002 CHEVROLET SILVERADO 2500HD PICKUP TRUCK. ON 12/11/09 WHILE DRIVING THE TRUCK, I APPLIED THE BRAKES AND THE PEDAL WENT COMPLETELY TO THE FLOOR, LEAVING ME WITH NO BRAKES. FORTUNATELY, I WAS GOING VERY SLOW AT THE TIME AND WAS ABLE TO ROLL TO A SLOW STOP WITH NO DAMAGE OR INJURY. I FOUND THAT MY BRAKE LINES WERE RUSTY WITH A HOLE ENTIRELY THROUGH ONE PLACE. I DID AN INTERNET SEARCH ON 'SILVERADO" AND 'RUSTY BRAKE LINES' AND FOUND NUMEROUS OTHER IRATE OWNERS WITH THE SAME PROBLEM. I CONTACTED GENERAL MOTORS AND WAS TOLD I WOULD NEED TO HAVE A DEALER INSPECT THE TRUCK BEFORE ANY ADDITIONAL ACTION COULD BE TAKEN. THIS IS THE RESULT: I WAS CHARGED $175.09 FOR HAULING THE VEHICLE 20 MILES TO THE NEAREST DEALER AND 'INSPECTING IT; YES, THE LINES WERE RUSTED OUT AS I HAD TOLD THEM; GENERAL MOTORS WILL PROVIDE NO FURTHER ACTION BECAUSE THE PROBLEM MAY BE THE RESULT OF 'LOW MILEAGE'; AND THE DEALER WANTS TO REPLACE THE BRAKE LINES FOR $1000.00. I LIVE IN NORTH CAROLINA AND HAVE DRIVEN AND WORKED ON VEHICLES FOR OVER 50 YEARS AND I HAVE NEVER BEFORE HAD A HOLE RUSTED IN A BRAKE LINE. THE SUDDEN AND UNEXPECTED LOSS OF BRAKES HAS TO BE A DEADLY DISASTER WAITING TO HAPPEN. *TR

NHTSA ODI #10298505

80,000 miles · Jan 1, 2010
Parking Brake

I HAVE A 2002, CHEVROLET C2500HD PICKUP. THE PARKING BRAKE DOESN'T WORK BECAUSE THE REAR AXLE SEALS ARE LEAKING GREASE ONTO THE PARKING BRAKE SHOES. THIS PROBLEM STARTED AT ABOUT 80,000 MILES. THE CHEVROLET DEALER SAID THERE ARE NO SERVICE DIFFICULTY REPORTS REGARDING THIS PROBLEM SO THEY WON'T FIX IT. THE DEALER SAID THE RE…

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I HAVE A 2002, CHEVROLET C2500HD PICKUP. THE PARKING BRAKE DOESN'T WORK BECAUSE THE REAR AXLE SEALS ARE LEAKING GREASE ONTO THE PARKING BRAKE SHOES. THIS PROBLEM STARTED AT ABOUT 80,000 MILES. THE CHEVROLET DEALER SAID THERE ARE NO SERVICE DIFFICULTY REPORTS REGARDING THIS PROBLEM SO THEY WON'T FIX IT. THE DEALER SAID THE REAR AXLE VENT IS OKAY AND THE AXLE IS NOT OVER FILLED. THE REAR AXLE SEALS SHOULD NOT BE LEAKING AT THIS LOW MILEAGE (BOTH AXLE SEALS ARE LEAKING). THE PICKUP HAS BEEN WELL CARED FOR, NO OFF ROAD USE, MOSTLY LIGHT PASSENGER HIGHWAY SERVICE WITH JUST A LITTLE TRAILER TOWING. THE REAR WHEEL BEARINGS ARE NOT NOISY AND HAVE VERY LITTLE PLAY. *TR

NHTSA ODI #10297757

74,834 miles · Dec 29, 2009
Engine And Engine Cooling

FUEL INJECTORS FAILED AND HAVE TO BE REPLACED. DUE TO PRIOR CLASS ACTION LAWSUIT WARRANTY WAS EXTENDED TO 200K MILES / 7 YEARS. AT 8 YEARS AND 75,000 MILES MINE FAILED. GM REFUSES TO REPLACE / EXTEND WARRANTY. MANY OTHER CUSTOMERS REPORT SAME PROBLEM AND RECURRING. COST TO REPAIR...$5200. GM SHOULD BE REQUIRED TO RECALL PA…

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FUEL INJECTORS FAILED AND HAVE TO BE REPLACED. DUE TO PRIOR CLASS ACTION LAWSUIT WARRANTY WAS EXTENDED TO 200K MILES / 7 YEARS. AT 8 YEARS AND 75,000 MILES MINE FAILED. GM REFUSES TO REPLACE / EXTEND WARRANTY. MANY OTHER CUSTOMERS REPORT SAME PROBLEM AND RECURRING. COST TO REPAIR...$5200. GM SHOULD BE REQUIRED TO RECALL PARTS, REIMBURSE CURRENT AND PRIOR REPAIRS. *TR

NHTSA ODI #10297308

75,100 miles · Dec 21, 2009
Service Brakes, Hydraulic

ABS SLOW STOP ACTIVATION, A COMMON COMPLAINT WITH CHEVROLET TRUCKS AND SUV,S, CHEVROLET HAS REFUSED TO FIX THE PROBLEM ALTHOUGH IT IS WELL DOCUMENTED AND SOME MODELS RECALLED FOR THE SAME DEFECT. *TR

NHTSA ODI #10296644

31,000 miles · Nov 21, 2009
Service Brakes, Hydraulic

MY 2002 CHEVROLET SILVERADO 2500 HD WAS HAVING A PROBLEM WITH THE ABS SYSTEM ACTIVATING AT SLOW SPEEDS WHEN THE WHEELS WERE NOT ACTUALLY SLIDING. ALTHOUGH THE WHEELS WERE ACTING EXACTLY AS DESCRIBED IN RECALL BULLETIN 05068C, I WAS TOLD BY THE DEALER THAT MY TRUCK WAS NOT COVERED EVEN IF THE PROBLEM WAS DUE TO FRONT WHEEL SPEED…

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MY 2002 CHEVROLET SILVERADO 2500 HD WAS HAVING A PROBLEM WITH THE ABS SYSTEM ACTIVATING AT SLOW SPEEDS WHEN THE WHEELS WERE NOT ACTUALLY SLIDING. ALTHOUGH THE WHEELS WERE ACTING EXACTLY AS DESCRIBED IN RECALL BULLETIN 05068C, I WAS TOLD BY THE DEALER THAT MY TRUCK WAS NOT COVERED EVEN IF THE PROBLEM WAS DUE TO FRONT WHEEL SPEED SENSOR CORROSION AS DESCRIBED IN THE RECALL. I ALSO CALLED THE GM CUSTOMER ASSISTANCE CENTER AT 800-630-2438 WHERE THEY ALSO SAID MY TRUCK IS NOT COVERED EVEN THOUGH THE VIN IS WITHIN THE BRACKETS IN THE RECALL. I WAS GIVEN A CASE NUMBER OF 71-774131746. I TOOK MY TRUCK TO LARSON CHEVROLET IN SUPERIOR, WI ON NOVEMBER 10, 2009 WHERE THEY INSPECTED MY FRONT WHEELS AND FOUND THE CORROSION DESCRIBED IN THE RECALL. I HAD THEM REPAIR THE CORROSION AT MY EXPENSE. I THEN CONTACTED CUSTOMER ASSISTANCE AGAIN AND THEY AGREED TO FORWARD MY CASE TO A DISTRICT SPECIALIST. AFTER A COUPLE CONVERSATIONS WITH THE DISTRICT SPECIALIST ISAAC I WAS TOLD THAT MY TRUCK WOULD NOT BE COVERED BECAUSE 3/4 TON TRUCKS WERE EXCLUDED. NO REASON FOR EXCLUDING 3/4 TON TRUCKS WAS GIVEN. IT SEEMS TO ME THAT GM WAS IN ERROR WHEN 3/4 TON TRUCKS WERE EXCLUDED BECAUSE MY TRUCK HAD THE EXACT PROBLEM DESCRIBED IN THE RECALL. I WOULD LIKE TO SEE THE RECALL EXPANDED TO INCLUDE 3/4 TON TRUCKS AND TO HAVE MY EXPENSES OF $206.47 REIMBURSED. *TR

NHTSA ODI #10293135

100,145 miles · Nov 13, 2009
Engine And Engine Cooling

I CURRENTLY DRIVE A 2002 CHEVY SILVERADO 2500HD WITH AN 8.1L ENGINE. I'VE NOW TAKEN MY TRUCK INTO FOUR DIFFERENT MECHANICS FOR THE SAME ISSUE. MY TRUCK WILL RANDOMLY SHUT OFF THE ENGINE. I'VE HAD IT SHUT OFF AT STOPLIGHTS, AT HIGHWAY SPEEDS, DRIVING AROUND TOWN, AND EVERYTHING IN-BETWEEN. OCCASIONALLY, IT WON'T EVEN START. …

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I CURRENTLY DRIVE A 2002 CHEVY SILVERADO 2500HD WITH AN 8.1L ENGINE. I'VE NOW TAKEN MY TRUCK INTO FOUR DIFFERENT MECHANICS FOR THE SAME ISSUE. MY TRUCK WILL RANDOMLY SHUT OFF THE ENGINE. I'VE HAD IT SHUT OFF AT STOPLIGHTS, AT HIGHWAY SPEEDS, DRIVING AROUND TOWN, AND EVERYTHING IN-BETWEEN. OCCASIONALLY, IT WON'T EVEN START. IT SOUNDS LIKE IT WANTS TO TURN OVER BUT TO NO AVAIL. AND WHEN IT STOPS, IT TAKES ABOUT 5 MINUTES TO FINALLY GET IT RESTARTED AND DRIVING AGAIN. OF COURSE, NO MECHANIC CAN EVER FIGURE OUT WHAT'S WRONG SINCE IT WON'T ACT UP IN THE SHOP. I'VE HAD THEM TELL ME IT COULD BE A HOST OF THINGS FROM AIR PROBLEMS TO FUEL LINE PROBLEMS TO ELECTRICAL ISSUES. NO ONE CAN GIVE ME A STRAIGHT ANSWER. I'VE EVEN HAD ONE MECHANIC DROP MY FUEL TANK TO INSPECT THE PUMP TO SEE IF IT'S THE PROBLEM. EVEN THEN, NOTHING ACTED UP. THERE NOW IS A CODE SHOWING UP SAYING MY CRANK SENSOR IS FAULTY. ALMOST EVERY MECHANIC IS CONVINCED IT'S MY FUEL PUMP BUT I HAVE GREAT PRESSURE IN THE LINES. I'VE NOTICED SEVERAL PEOPLE WITH MY SAME YEAR AND ENGINE HAVE HAD SIMILAR ISSUES. AS WELL, I NOTICED THERE WAS A RECALL FOR THE CRANK SENSORS ON 2001 MODELS BUT NOT 2002 MODELS. WHY IS THIS? I THINK THERE'S JUST AS MANY ISSUES IN THAT YEAR AS THERE ARE IN FOLLOWING YEARS. THIS ISSUE CAN BE A REAL PROBLEM IF I LOSE POWER STEERING AND WRECK DUE TO THE ENGINE SHUTTING OFF! HOW IS THIS NOT A RECALL FOR 2002 AND YET A RECALL FOR 2001? I HAVE YET TO SEE A SES LIGHT GO ON FOR THIS ISSUE. I'VE GOT JUST OVER 100,000 MILES ON THIS TRUCK. PLEASE TELL ME THAT THIS WILL BE A RECALL OR AT LEAST THIS IS THE ISSUE SURROUNDING MY PROBLEMS! *TR

NHTSA ODI #10292130

91,968 miles · Sep 24, 2009
Fuel System, Other

TL* THE CONTACT OWNS A 2002 CHEVROLET SILVERADO 2500 HD. WHILE DRIVING 65 MPH THE VEHICLE STALLED WITHOUT ANY PRIOR WARNINGS. WHILE COASTING TO THE EMERGENCY LANE, THE ENGINE WARNING LIGHT ILLUMINATED ON THE INSTRUMENT CONTROL PANEL. THE VEHICLE WAS TAKEN TO THE DEALER AND A TECHNICIAN CONCLUDED THAT THE FUEL INJECTORS FAILED. T…

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TL* THE CONTACT OWNS A 2002 CHEVROLET SILVERADO 2500 HD. WHILE DRIVING 65 MPH THE VEHICLE STALLED WITHOUT ANY PRIOR WARNINGS. WHILE COASTING TO THE EMERGENCY LANE, THE ENGINE WARNING LIGHT ILLUMINATED ON THE INSTRUMENT CONTROL PANEL. THE VEHICLE WAS TAKEN TO THE DEALER AND A TECHNICIAN CONCLUDED THAT THE FUEL INJECTORS FAILED. THE VEHICLE IS IN THE PROCESS OF BEING REPAIRED AT THE OWNERS EXPENSE. THE FAILURE MILEAGE WAS 91968 AND THE CURRENT MILEAGE WAS 92000. UPDATED 3/17/10 *CN UPDATED 05/06/10

NHTSA ODI #10285146

66,284 miles · Sep 23, 2009
Service Brakes, Hydraulic

AFTER TRAVELING ON THE HIGHWAY FOR SIXTY MILES, THE TRUCK WAS BAKED FOR TRAFFIC AT HIGHWAY EXIT. THE BAKE PEDAL WENT DOWN ALMOST TO THE FLOOR. THE TRUCK DID SLOW DOWN, BUT BRAKING WAS NOT NORMAL. UPON INSPECTION IT WAS FOUND THAT THE BRAKE LINES COMING THE MASTER CYLINDER TO THE ABS AND FROM THE ABS TO THE FRONT BRAKES WERE RUST…

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AFTER TRAVELING ON THE HIGHWAY FOR SIXTY MILES, THE TRUCK WAS BAKED FOR TRAFFIC AT HIGHWAY EXIT. THE BAKE PEDAL WENT DOWN ALMOST TO THE FLOOR. THE TRUCK DID SLOW DOWN, BUT BRAKING WAS NOT NORMAL. UPON INSPECTION IT WAS FOUND THAT THE BRAKE LINES COMING THE MASTER CYLINDER TO THE ABS AND FROM THE ABS TO THE FRONT BRAKES WERE RUSTED AND ONE LINE HAD A HOLE AND WAS LEAKING. FOUR BRAKE LINES WERE REPLACED. *TR

NHTSA ODI #10284983

62,389 miles · Sep 22, 2009
Fuel System, Gasoline

TL*THE CONTACT OWNS A 2002 CHEVROLET SILVERADO 2500 HD. THE CONTACT STATED THAT THE FUEL INJECTORS HAVE FAILED. WHILE DRIVING APPROXIMATELY 35 MPH, THE VEHICLE SHUT OFF ON THE HIGHWAY. THE CONTACT WAS UNABLE TO RESTART THE VEHICLE AND IT WAS TOWED TO HER RESIDENCE. A WARNING LIGHT ILLUMINATED ON THE DASHBOARD PRIOR TO THE ENGINE…

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TL*THE CONTACT OWNS A 2002 CHEVROLET SILVERADO 2500 HD. THE CONTACT STATED THAT THE FUEL INJECTORS HAVE FAILED. WHILE DRIVING APPROXIMATELY 35 MPH, THE VEHICLE SHUT OFF ON THE HIGHWAY. THE CONTACT WAS UNABLE TO RESTART THE VEHICLE AND IT WAS TOWED TO HER RESIDENCE. A WARNING LIGHT ILLUMINATED ON THE DASHBOARD PRIOR TO THE ENGINE SHUTTING OFF. THE DEALER WAS UNABLE TO DIAGNOSE THE FAILURE. A DISTRICT MANAGER STATED THAT THERE WAS NOTHING THEY COULD DO TO CORRECT THE FAILURE SINCE THE DEALER WAS UNABLE TO DUPLICATE OR DIAGNOSE THE FAILURE. THE FAILURE MILEAGE WAS 62,389.

NHTSA ODI #10284939

82,937 miles · Aug 18, 2009
Service Brakes, Hydraulic

THE REAR BRAKE LINE ON MY 2002 CHEVROLET SILVERADO 2500HD RUSTED OUT AND FAILED WHILE TOWING MY FIFTH WHEEL CAMPER.FORTUNATLY THE CAMPER BRAKES WERE FUNCTIONING PROPERLY AND I WAS ABLE TO STOP WITHOUT INCIDENT. I REMOVED AND REPLACED THE REAR BRAKE LINE WHEN I GOT THE TRUCK HOME.AS I WAS PUMPING THE BRAKES TO BLEED THE AIR OUT O…

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THE REAR BRAKE LINE ON MY 2002 CHEVROLET SILVERADO 2500HD RUSTED OUT AND FAILED WHILE TOWING MY FIFTH WHEEL CAMPER.FORTUNATLY THE CAMPER BRAKES WERE FUNCTIONING PROPERLY AND I WAS ABLE TO STOP WITHOUT INCIDENT. I REMOVED AND REPLACED THE REAR BRAKE LINE WHEN I GOT THE TRUCK HOME.AS I WAS PUMPING THE BRAKES TO BLEED THE AIR OUT OF THE NEW LINE THE RIGHT FRONT LINE FAILED.IT WAS AT THIS TIME THAT I REALIZED HOW LUCKY I WAS TO HAVE AVOIDED A POTENTIALLY DEADLY INCIDENT. UPON INSPECTION OF THE REST OF THE LINES I FOUND THEM ALL TO BE RUSTED TO THE POINT THAT I WILL BE REPLACING ALL OF THE LINES ON THE TRUCK. *TR

NHTSA ODI #10280916

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.