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2002 GMC Sierra 2500

Owner reports · Recalls · Investigations

More warning signs than most Sierra 2500 years

Owner complaints for the 2002 GMC Sierra 2500 are substantially higher than the model-year median of 46.

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When problems were reported

Mileage at the reported incident

114 reports with mileage · 20 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 44 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes. Review the 32 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Power Train. Review the 14 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

10 crash reports1 fire reports5 injury reports

Service Brakes, Hydraulic complaints

44 reports
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40,000 miles · Oct 18, 2005
Service Brakes, Hydraulic

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…

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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. *JB

NHTSA ODI #10140116

Mileage unknown · Jul 8, 2005
Power TrainService Brakes, Hydraulic

DT: THE CONTACT COMPLAINED ABOUT A BRAKE PROBLEM. REAR ROTORS RUSTED. DEALERSHIP SAID THAT THIS WAS NORMAL WEAR FOR THE REAR ROTORS. THE GM CUSTOMER SERVICE TOLD HIM TO TAKE IT BACK TO THE DEALER, AND ALL THEY WOULD TELL HIM WAS THAT HE NEEDED TO REPLACE ROTORS AND REAR BRAKE PADS BECAUSE THEY COULD NOT TURN THEM OVER. *…

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DT: THE CONTACT COMPLAINED ABOUT A BRAKE PROBLEM. REAR ROTORS RUSTED. DEALERSHIP SAID THAT THIS WAS NORMAL WEAR FOR THE REAR ROTORS. THE GM CUSTOMER SERVICE TOLD HIM TO TAKE IT BACK TO THE DEALER, AND ALL THEY WOULD TELL HIM WAS THAT HE NEEDED TO REPLACE ROTORS AND REAR BRAKE PADS BECAUSE THEY COULD NOT TURN THEM OVER. *AK LEFT REAR AXLE SEAL LEAKED. THE SLIP YOKE AND REAR U-JOINT ON THE REAR DRIVESHAFT WERE REPLACED BECAUSE THEY WERE CAUSING A CHATTERING FEELING WHEN THE WHEEL WAS TURNED. *NM

NHTSA ODI #10124854

Mileage unknown · May 16, 2005
Service Brakes, Hydraulic

RIGHT REAR BRAKE OF 2002 GMC SIVERADO 2500HD DOES NOT RELEASE COMPLETELY. RIM GETS HOT AND BRAKES SMOKE. GM DEALER ON SECOND SERVICE PROBLEM INSTALLED COVERS OVER THE BRAKES TO KEEP ROAD GRIM OUT. THIS DOES NOT SEEM TO FIX THE PROBLEM. JUST DROPPED OFF TRUCK FOR THE THIRD TIME WITH THE SAME ISSUES AND THEY CAN NOT FIND ANY PROBL…

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RIGHT REAR BRAKE OF 2002 GMC SIVERADO 2500HD DOES NOT RELEASE COMPLETELY. RIM GETS HOT AND BRAKES SMOKE. GM DEALER ON SECOND SERVICE PROBLEM INSTALLED COVERS OVER THE BRAKES TO KEEP ROAD GRIM OUT. THIS DOES NOT SEEM TO FIX THE PROBLEM. JUST DROPPED OFF TRUCK FOR THE THIRD TIME WITH THE SAME ISSUES AND THEY CAN NOT FIND ANY PROBLEMS. RIM IS DESTROYED DUE TO HEAT AND BRAKE DUST. TRUCK HAS 11,000 MILES ON IT

NHTSA ODI #10121113

11,800 miles · Jun 26, 2003
Service Brakes, Hydraulic

THE BRAKE LINE FAILED, WHICH CAUSED THE VEHICLE TO EXPERIENCE EXTENDED STOPPING DISTANCE. *JB THE BRAKE LINE CONTAINED A BEND, WHICH WAS SUSCEPTIBLE TO BEING SNAGGED. THE CONSUMER REPAIRED THE BRAKE LINE HIMSELF. *JB

NHTSA ODI #10019805

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

3

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.

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.