IllustrationBROKEN EXHAUST MANIFOLD STUDS ARE CAUSING ENVIRONMENTAL HAZARD AND MAY LEAD TO FAILED CATALYTIC CONVERTER AND OTHER ENGINE PROBLEMS. THIS IS A MANUFACTURING DEFECT THAT SHOULD BE RECALLED, AS IT RENDERS THE VEHICLE EITHER UNUSABLE OR UNABLE TO PASS ENVIRONMENTAL TESTING. *TR
2002 GMC Yukon Xl
Owner reports · Recalls · Investigations
Similar to other model years
Owner complaints for the 2002 GMC Yukon Xl do not stand out strongly from the model-year median of 68.
About this comparison →How this year compares
Owner complaints by model year
Compare all Yukon Xl years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
200–25K
1025–50K
1950–75K
1375–100K
9100–150K
9150K+
80 reports with mileage · 15 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 19 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Engine And Engine Cooling. Review the 10 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Fuel System, Gasoline. Review the 10 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
5 crash reports1 fire reports2 injury reports
Fuel System, Gasoline complaints
10 reportsVEHICLE RAN OUT OF GAS, FUEL GAUGE READ 1/4 TANK
2002 GMC YUKON XL FUEL PUMP FAILURE. ECMB FUSE WAS BLOWN WHICH RUNS THE FUEL PUMP. FUEL PRESSURE WAS FOUND AT 24 PSI. THIS ENGINE REQUIRES 55-62 PSI. CURRENT DRAW ON THE PUMP IS AT 9 AMPS. THIS IS WAY TOO HIGH. TRUCK WAS STARTED AFTER REPLACING FUSE, BUT RUNS BADLY AND STALLS OUT. TRUCK IS NOT UNDER WARRANTY, BECAUSE THE DEALE…
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2002 GMC YUKON XL FUEL PUMP FAILURE. ECMB FUSE WAS BLOWN WHICH RUNS THE FUEL PUMP. FUEL PRESSURE WAS FOUND AT 24 PSI. THIS ENGINE REQUIRES 55-62 PSI. CURRENT DRAW ON THE PUMP IS AT 9 AMPS. THIS IS WAY TOO HIGH. TRUCK WAS STARTED AFTER REPLACING FUSE, BUT RUNS BADLY AND STALLS OUT. TRUCK IS NOT UNDER WARRANTY, BECAUSE THE DEALERSHIP FILLED OUT WRONG PAPERWORK AT THE TIME OF PURCHASE. THE CONTRACT WAS DENIED BECAUSE OF THIS ERROR. COST FOR REPLACING FUEL PUMP IS $950.00. TRUCK IS STILL NOT FIXED. JB
DT*: THE CONTACT STATED WHEN THE FUEL TANK HAS LESS THAN A QUARTER OF A TANK OF GASOLINE, THE VEHICLE WOULD NOT START UNLESS MORE GASOLINE WAS ADDED TO THE TANK. THE VEHICLE WAS SEEN BY A DEALER AND THE FUEL PUMP WAS REPLACED. THERE IS A NHTSA RECALL, # 05V155000, REGARDING THE FUEL SYSTEM. THE VEHICLE HAS THE SAME PROBLEMS …
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DT*: THE CONTACT STATED WHEN THE FUEL TANK HAS LESS THAN A QUARTER OF A TANK OF GASOLINE, THE VEHICLE WOULD NOT START UNLESS MORE GASOLINE WAS ADDED TO THE TANK. THE VEHICLE WAS SEEN BY A DEALER AND THE FUEL PUMP WAS REPLACED. THERE IS A NHTSA RECALL, # 05V155000, REGARDING THE FUEL SYSTEM. THE VEHICLE HAS THE SAME PROBLEMS AS INDICATED IN THE RECALL; HOWEVER IT IS NOT INCLUDED IN THE RECALL DUE TO THE VIN. UPDATED 05/10/06. *JB
ORIGINAL PROBLEM: MY 2002 YUKON XL WAS RUNNING POORLY WHEN THE WEATHER TURNED COLD - BELOW 30 DEGREES. PROBLEM DIAGNOSED AS FAULTY INTAKE GASKETS DUE TO IMPROPER DESIGN. SECOND PROBLEM: IT BECAME HARD TO START, AND A COUPLE OF DAYS LATER, IT WOULD NOT START AT ALL. PROBLEM DIAGNOSED AS FAULTY FUEL PUMP. BOTH PROBLEMS ARE BECAUSE…
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ORIGINAL PROBLEM: MY 2002 YUKON XL WAS RUNNING POORLY WHEN THE WEATHER TURNED COLD - BELOW 30 DEGREES. PROBLEM DIAGNOSED AS FAULTY INTAKE GASKETS DUE TO IMPROPER DESIGN. SECOND PROBLEM: IT BECAME HARD TO START, AND A COUPLE OF DAYS LATER, IT WOULD NOT START AT ALL. PROBLEM DIAGNOSED AS FAULTY FUEL PUMP. BOTH PROBLEMS ARE BECAUSE THEY WERE DESIGNED FOR USE WITH ETHANOL OR UNLEADED GAS. I ONLY USE UNLEADED (NEVER HAVE SEEN A STATION THAT SELLS ETHANOL). IF YOUR GM VEHICLE HAS A 5.3L V8 ENGINE, AND THE VIN HAS A Z IN THE 8TH POSITION, BE AWARE THAT THIS MIGHT HAPPEN TO YOUR VEHICLE. IF NOT UNDER WARRANTY, IT IS VERY COSTLY! THE GASKETS AND THE FUEL PUMP ALONE COST OVER $630. LABOR OVER $500. *NM
SEVERAL INSTANCES OF VEHICAL STALLING, NOT STARTING OR RUNNIONG PROPERLY DUE TO FUEL PUMP
VEHICLE WOULD NOT START. FUEL PUMP WAS DEFECTIVE. HAD FUEL PUMP REPLACED.
FUEL TANK LEAKS WHEN FILLED BEYOND 2/3-3/4 FULL. GAS TANK LEAKED GAS ON GARAGE FLOOR DAMAGING COATED/SEALED FLOOR. FORTUNATELY LEAKAGE WAS DISCOVERED BEFORE IT WAS ABLE TO IGNITE. VEHICLE WAS TAKEN TO DEALER AND I WAS ADVISED THAT IN FACT THE PROBLEM WAS A FAULTY GAS TANK. I WAS ALSO ADVISED INITIALLY THAT A REPLACEMENT TANK W…
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FUEL TANK LEAKS WHEN FILLED BEYOND 2/3-3/4 FULL. GAS TANK LEAKED GAS ON GARAGE FLOOR DAMAGING COATED/SEALED FLOOR. FORTUNATELY LEAKAGE WAS DISCOVERED BEFORE IT WAS ABLE TO IGNITE. VEHICLE WAS TAKEN TO DEALER AND I WAS ADVISED THAT IN FACT THE PROBLEM WAS A FAULTY GAS TANK. I WAS ALSO ADVISED INITIALLY THAT A REPLACEMENT TANK WOULD NOT BE AVAILABLE UNTIL JANUARY, 2004. AS IT TURNS OUT, THEY OBVIOUSLY HAVE HAD A SIGNIFICANT NUMBER OF THESE COMPLAINTS AND I SUSPECT THAT THEY HAVE HAD TO REDESIGN AND PRODUCE A SAFER REPLACEMENT TANK. MY DEALER HAS REPLACED "SEVERAL" OF THESE TANKS. WHY WAS THERE NOT A NOTICE SENT OUT TO THE OWNERS OF THESE VEHICLES WHEN THEY ARE AWARE OF THE SIGNIFICANCE OF THE PROBLEM. ARE WE GOING TO HAVE TO WAIT UNTIL THE LEAKAGE OF FUEL IN OUR GARAGES IS IGNITED WITH A WATER HEATER COMING ON WHILE WE ARE SLEEPING? THIS PROBLEM MUST BE ADDRESSED IMMEDIATELY. I PURCHASED ANOTHER IDENTICAL YUKON XL WITH MY DAUGHTER FROM THIS SAME DEALER. THIS VEHICLE IS CURRENTLY OUT OF SERVICE AT THE DEALERS LOCATION WAITING FOR A REPLACEMENT GAS TANK. *LA
THE CONSUMER HAD DIFFICULTY FILLING THE GAS TANK. THE CONSUMER NOTICED THE TANK HAD TO BE FILLED SLOWLY. WHEN REACHING ABOUT 3/4 FULL, FUEL LEAKED OUT. CONSUMER CONTACTED GM THEY CLAIMED THERE WAS A BULLETIN OUT REGARDING THE PROBLEM AND THE DEALERSHIP NEVER FIXED THE VEHICLE. CONSUMER FELT GM SHOULD ISSUE A RECALL ON THE D…
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THE CONSUMER HAD DIFFICULTY FILLING THE GAS TANK. THE CONSUMER NOTICED THE TANK HAD TO BE FILLED SLOWLY. WHEN REACHING ABOUT 3/4 FULL, FUEL LEAKED OUT. CONSUMER CONTACTED GM THEY CLAIMED THERE WAS A BULLETIN OUT REGARDING THE PROBLEM AND THE DEALERSHIP NEVER FIXED THE VEHICLE. CONSUMER FELT GM SHOULD ISSUE A RECALL ON THE DEFECTIVE VEHICLE. *AK *CB *JB
2000 GMC YUKON XL. FUEL LEAK IN MY GARAGE AFTER FILLING GAS TANK. LEAKED AT LEAST 6-8 GALLONS OF FUEL INTO GARAGE. SERVICE FACILITY DIAGNOSED PROBLEM TO BE FAULTY PLUNGER IN FUEL PUMP. VERY DANGEROUS, SINCE MY GARAGE CONTAINS GAS HOT WATER HEATER WITH PILOT. HAZARDOUS MATERIAL CLEANUP (REQUIRED BY FIRE DEPARTMENT) COST $160…
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2000 GMC YUKON XL. FUEL LEAK IN MY GARAGE AFTER FILLING GAS TANK. LEAKED AT LEAST 6-8 GALLONS OF FUEL INTO GARAGE. SERVICE FACILITY DIAGNOSED PROBLEM TO BE FAULTY PLUNGER IN FUEL PUMP. VERY DANGEROUS, SINCE MY GARAGE CONTAINS GAS HOT WATER HEATER WITH PILOT. HAZARDOUS MATERIAL CLEANUP (REQUIRED BY FIRE DEPARTMENT) COST $1600. *NLM
Official recalls
105V379000 · Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip
Aug 29, 2005
CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES MAY EXPERIENCE UNWANTED ANTILOCK BRAKE SYSTEM (ABS) ACTIVATION. THIS CONDITION IS MORE LIKELY TO OCCUR IN ENVIRONMENTALLY CORROSIVE AREAS. THIS RECALL WILL BE LAUNCHED IN THE "SALT BELT" STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MARYLAND, MASSACHUSETTS, MAINE, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN AND THE DISTRICT OF COLUMBIA ONLY.
Consequence & remedy
Consequence: THIS CAN CAUSE INCREASED STOPPING DISTANCES DURING LOW-SPEED BRAKE APPLICATIONS, WHICH COULD RESULT IN A CRASH.
Remedy: DEALERS ARE TO REMOVE THE WHEEL SPEED SENSOR AND THOROUGHLY CLEAN THE WHEEL SPEED SENSOR MOUNTING SURFACE ON THE BEARING, APPLY RUST INHIBITOR TO THE CLEANED SURFACE, GREASE THE MOUNTING SURFACE, REINSTALL THE WHEEL SPEED SENSOR, AND CHECK THE PEAK-TO-PEAK OUTPUT VOLTAGE TO ENSURE THE WHEEL SPEED SIGNAL IS WITHIN SPECIFICATIONS. THE RECALL BEGAN SEPTEMBER 22, 2005. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438 OR GMC AT 1-866-996-9463.
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
3DP05009 · Parking Brake Failure
Opened Dec 20, 2005 · Closed May 31, 2006
Status: closed (inferred from source dates) · Parking Brake; Parking Brake:conventional; Parking Brake:conventional:mechanical
ODI'S REVIEW OF COMPLAINT DATA RECEIVED SINCE THE CLOSE OF EA04-011 REVEALED NO INDICATION THAT THE INVESTIGATION SHOULD BE RE-OPENED.MORE DETAILS CAN BE FOUND IN THE FEDERAL REGISTER NOTICE ENCLOSED IN THE DP05-009 PUBLIC FILE.ODI RESERVES THE RIGHT TO REOPEN THE INVESTIGATION IN THE FUTURE SHOULD CONDITIONS WARRANT.
Additional source detail variants (3)
Parking Brake:conventional
ODI'S REVIEW OF COMPLAINT DATA RECEIVED SINCE THE CLOSE OF EA04-011 REVEALED NO INDICATION THAT THE INVESTIGATION SHOULD BE RE-OPENED.MORE DETAILS CAN BE FOUND IN THE FEDERAL REGISTER NOTICE ENCLOSED IN THE DP05-009 PUBLIC FILE.ODI RESERVES THE RIGHT TO REOPEN THE INVESTIGATION IN THE FUTURE SHOULD CONDITIONS WARRANT.
Parking Brake:conventional:mechanical
ODI'S REVIEW OF COMPLAINT DATA RECEIVED SINCE THE CLOSE OF EA04-011 REVEALED NO INDICATION THAT THE INVESTIGATION SHOULD BE RE-OPENED.MORE DETAILS CAN BE FOUND IN THE FEDERAL REGISTER NOTICE ENCLOSED IN THE DP05-009 PUBLIC FILE.ODI RESERVES THE RIGHT TO REOPEN THE INVESTIGATION IN THE FUTURE SHOULD CONDITIONS WARRANT.
Parking Brake
ODI'S REVIEW OF COMPLAINT DATA RECEIVED SINCE THE CLOSE OF EA04-011 REVEALED NO INDICATION THAT THE INVESTIGATION SHOULD BE RE-OPENED.MORE DETAILS CAN BE FOUND IN THE FEDERAL REGISTER NOTICE ENCLOSED IN THE DP05-009 PUBLIC FILE.ODI RESERVES THE RIGHT TO REOPEN THE INVESTIGATION IN THE FUTURE SHOULD CONDITIONS WARRANT.
PE05020 · Unwanted LOW-SPEED Abs Activation
Opened Apr 28, 2005 · Closed Sep 13, 2005
Status: closed (inferred from source dates) · Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip; Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module
IN A LETTER DATED AUGUST 29, 2005, GM NOTIFIED ODI THAT IT WAS RECALLING CERTAIN MODEL YEAR 1999 THROUGH 2002 C/K PICKUP TRUCKS AND SPORT UTILITY VEHICLES TO CORRECT A PROBLEM WITH ANTI-LOCK BRAKE SYSTEM (ABS) WHEEL SPEED SENSOR CORROSION THAT MAY RESULT IN UNWANTED ABS ACTIVATION AND EXTENDED STOPPING DISTANCES DURING LOW-SPEED BRAKING (RECALL 05V-379).GM'S RECALL COVERS APPROXIMATELY 804,000 VEHICLES CURRENTLY REGISTERED IN THE FOLLOWING 14 SALT-BELT STATES:CONNECTICUT, ILLINOIS, INDIANA, MASSACHUSETTS, MAINE, MICHIGAN, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, AND WEST VIRGINIA.THE RECALL PROCEDURE WILL INVOLVE REMOVING THE SENSOR, CLEANING THE MOUNTING SURFACE, APPLYING A RUST INHIBITOR (ZINC-X) TO THE SURFACE, AND REINSTALLING THE SENSOR.IF NECESSARY, THE SENSOR WILL BE REPLACED. THE POPULATION AND FAILURE REPORT DATA GIVEN IN THIS RESUME ARE FOR THE FULL REGION THAT HAS BEEN CONSIDERED BY ODI AS THE SALT-BELT.THAT INCLUDES DELAWARE, IOWA, MARYLAND, MINNESOTA, MISSOURI, WISCONSIN AND THE DISTRICT OF COLUMBIA IN ADDITION TO THE 14 STATES INCLUDED IN 05V-379.THE STATES COVERED BY GM'S RECALL HAVE THE HIGHEST INCIDENT RATES FOR THE SUBJECT CONDITION, ACCOUNTING FOR 91% OF THE INCIDENTS, BUT ONLY 24% OF SUBJECT VEHICLE SALES IN THE UNITED STATES.ODI'S ANALYSIS DETERMINED THAT 840 OF THE COMPLAINTS, 244 OF THE CRASHES, AND 16 OF THE INJURIES IDENTIFIED IN THIS INVESTIGATION OCCURRED IN THOSE STATES.THE RESULTING INCIDENT AND CRASH RATES ARE 96.2 AND 28.0 PER 100,000 VEHICLES RESPECTIVELY (NOTE:RATES ARE BASED ON VEHICLE SALES, NOT REGISTERED VEHICLES). THE CORRESPONDING NUMBERS IN THE EXCLUDED PORTIONS OF THE SALT-BELT ARE 399,000 VEHICLES, 81 INCIDENTS (20.3 PER 100,000 VEHICLES), 3 CRASHES, AND NO INJURIES.THE STATISTICS IN THE REMAINING 30 STATES ARE 2,406,000 VEHICLES, 168 INCIDENTS (7.0 PER 100,000 VEHICLES), 31 CRASHES, AND ONE INJURY.GM AND ODI ARE CONTINUING TO MONITOR THE PROBLEM EXPERIENCE IN STATES THAT ARE NOT INCLUDED IN THE RECALL.GM WILL PROVIDE ODI WITH UPDATED COMPLAINT, FIELD REPORT, AND WARRANTY DATA IN NOVEMBER 2005.ODI AND GM WILL REVIEW THAT DATA AND ASSESS THE APPROPRIATENESS OF THE CURRENT SCOPE OF THE RECALL AT THAT TIME.
Additional source detail variants (2)
Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module
IN A LETTER DATED AUGUST 29, 2005, GM NOTIFIED ODI THAT IT WAS RECALLING CERTAIN MODEL YEAR 1999 THROUGH 2002 C/K PICKUP TRUCKS AND SPORT UTILITY VEHICLES TO CORRECT A PROBLEM WITH ANTI-LOCK BRAKE SYSTEM (ABS) WHEEL SPEED SENSOR CORROSION THAT MAY RESULT IN UNWANTED ABS ACTIVATION AND EXTENDED STOPPING DISTANCES DURING LOW-SPEED BRAKING (RECALL 05V-379).GM'S RECALL COVERS APPROXIMATELY 804,000 VEHICLES CURRENTLY REGISTERED IN THE FOLLOWING 14 SALT-BELT STATES:CONNECTICUT, ILLINOIS, INDIANA, MASSACHUSETTS, MAINE, MICHIGAN, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, AND WEST VIRGINIA.THE RECALL PROCEDURE WILL INVOLVE REMOVING THE SENSOR, CLEANING THE MOUNTING SURFACE, APPLYING A RUST INHIBITOR (ZINC-X) TO THE SURFACE, AND REINSTALLING THE SENSOR.IF NECESSARY, THE SENSOR WILL BE REPLACED. THE POPULATION AND FAILURE REPORT DATA GIVEN IN THIS RESUME ARE FOR THE FULL REGION THAT HAS BEEN CONSIDERED BY ODI AS THE SALT-BELT.THAT INCLUDES DELAWARE, IOWA, MARYLAND, MINNESOTA, MISSOURI, WISCONSIN AND THE DISTRICT OF COLUMBIA IN ADDITION TO THE 14 STATES INCLUDED IN 05V-379.THE STATES COVERED BY GM'S RECALL HAVE THE HIGHEST INCIDENT RATES FOR THE SUBJECT CONDITION, ACCOUNTING FOR 91% OF THE INCIDENTS, BUT ONLY 24% OF SUBJECT VEHICLE SALES IN THE UNITED STATES.ODI'S ANALYSIS DETERMINED THAT 840 OF THE COMPLAINTS, 244 OF THE CRASHES, AND 16 OF THE INJURIES IDENTIFIED IN THIS INVESTIGATION OCCURRED IN THOSE STATES.THE RESULTING INCIDENT AND CRASH RATES ARE 96.2 AND 28.0 PER 100,000 VEHICLES RESPECTIVELY (NOTE:RATES ARE BASED ON VEHICLE SALES, NOT REGISTERED VEHICLES). THE CORRESPONDING NUMBERS IN THE EXCLUDED PORTIONS OF THE SALT-BELT ARE 399,000 VEHICLES, 81 INCIDENTS (20.3 PER 100,000 VEHICLES), 3 CRASHES, AND NO INJURIES.THE STATISTICS IN THE REMAINING 30 STATES ARE 2,406,000 VEHICLES, 168 INCIDENTS (7.0 PER 100,000 VEHICLES), 31 CRASHES, AND ONE INJURY.GM AND ODI ARE CONTINUING TO MONITOR THE PROBLEM EXPERIENCE IN STATES THAT ARE NOT INCLUDED IN THE RECALL.GM WILL PROVIDE ODI WITH UPDATED COMPLAINT, FIELD REPORT, AND WARRANTY DATA IN NOVEMBER 2005.ODI AND GM WILL REVIEW THAT DATA AND ASSESS THE APPROPRIATENESS OF THE CURRENT SCOPE OF THE RECALL AT THAT TIME.
Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip
IN A LETTER DATED AUGUST 29, 2005, GM NOTIFIED ODI THAT IT WAS RECALLING CERTAIN MODEL YEAR 1999 THROUGH 2002 C/K PICKUP TRUCKS AND SPORT UTILITY VEHICLES TO CORRECT A PROBLEM WITH ANTI-LOCK BRAKE SYSTEM (ABS) WHEEL SPEED SENSOR CORROSION THAT MAY RESULT IN UNWANTED ABS ACTIVATION AND EXTENDED STOPPING DISTANCES DURING LOW-SPEED BRAKING (RECALL 05V-379).GM'S RECALL COVERS APPROXIMATELY 804,000 VEHICLES CURRENTLY REGISTERED IN THE FOLLOWING 14 SALT-BELT STATES:CONNECTICUT, ILLINOIS, INDIANA, MASSACHUSETTS, MAINE, MICHIGAN, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, AND WEST VIRGINIA.THE RECALL PROCEDURE WILL INVOLVE REMOVING THE SENSOR, CLEANING THE MOUNTING SURFACE, APPLYING A RUST INHIBITOR (ZINC-X) TO THE SURFACE, AND REINSTALLING THE SENSOR.IF NECESSARY, THE SENSOR WILL BE REPLACED. THE POPULATION AND FAILURE REPORT DATA GIVEN IN THIS RESUME ARE FOR THE FULL REGION THAT HAS BEEN CONSIDERED BY ODI AS THE SALT-BELT.THAT INCLUDES DELAWARE, IOWA, MARYLAND, MINNESOTA, MISSOURI, WISCONSIN AND THE DISTRICT OF COLUMBIA IN ADDITION TO THE 14 STATES INCLUDED IN 05V-379.THE STATES COVERED BY GM'S RECALL HAVE THE HIGHEST INCIDENT RATES FOR THE SUBJECT CONDITION, ACCOUNTING FOR 91% OF THE INCIDENTS, BUT ONLY 24% OF SUBJECT VEHICLE SALES IN THE UNITED STATES.ODI'S ANALYSIS DETERMINED THAT 840 OF THE COMPLAINTS, 244 OF THE CRASHES, AND 16 OF THE INJURIES IDENTIFIED IN THIS INVESTIGATION OCCURRED IN THOSE STATES.THE RESULTING INCIDENT AND CRASH RATES ARE 96.2 AND 28.0 PER 100,000 VEHICLES RESPECTIVELY (NOTE:RATES ARE BASED ON VEHICLE SALES, NOT REGISTERED VEHICLES). THE CORRESPONDING NUMBERS IN THE EXCLUDED PORTIONS OF THE SALT-BELT ARE 399,000 VEHICLES, 81 INCIDENTS (20.3 PER 100,000 VEHICLES), 3 CRASHES, AND NO INJURIES.THE STATISTICS IN THE REMAINING 30 STATES ARE 2,406,000 VEHICLES, 168 INCIDENTS (7.0 PER 100,000 VEHICLES), 31 CRASHES, AND ONE INJURY.GM AND ODI ARE CONTINUING TO MONITOR THE PROBLEM EXPERIENCE IN STATES THAT ARE NOT INCLUDED IN THE RECALL.GM WILL PROVIDE ODI WITH UPDATED COMPLAINT, FIELD REPORT, AND WARRANTY DATA IN NOVEMBER 2005.ODI AND GM WILL REVIEW THAT DATA AND ASSESS THE APPROPRIATENESS OF THE CURRENT SCOPE OF THE RECALL AT THAT TIME.
EA02015 · Throttle Sticking Closed
Opened Aug 1, 2002 · Closed Jan 12, 2004
Status: closed (inferred from source dates) · Vehicle Speed Control:linkages
THIS INVESTIGATION INVOLVES THE GENERAL MOTORS CORPORATION (GM)THROTTLE BODY (TB) UTILIZED IN MODEL YEAR (MY) 1999-2002 SILVERADO, SIERRA, TAHOE, SUBURBAN, AVALANCHE AND YUKON (SUBJECT VEHICLE(S)) WITH 4.8L, 5.3L, AND 6.0L ENGINES. THE TB VALVE MAY INTERMITTENTLY STICK IN A CLOSED POSITION.IN SUCH A SITUATION, AN OPERATOR MAY APPLY ADDITIONAL ACCELERATOR PEDAL FORCE TO INCREASE ENGINE SPEED.THE APPLICATION OF ADDITIONAL ACCELERATOR PEDAL FORCE, TO OPEN A STUCK THROTTLE VALVE, MAY OPEN THE THROTTLE VALVE MORE THAN INTENDED AND, IN TURN, ACCELERATE THE ENGINE AND VEHICLE MORE THAN INTENDED AND REASONABLY EXPECTED BY THE DRIVER.ON AUGUST 1, 2002, THE OFFICE OF DEFECTS INVESTIGATION (ODI), OF THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION (NHTSA), OPENED THIS ENGINEERING ANALYSIS.THE INVESTIGATION REVEALED THAT TWO FACTORS MAY CAUSE THE DEFECT: 1) TB MANUFACTURING PROCESS PROBLEMS; AND 2) ACCUMULATION OF DEPOSITS (A PCV SYSTEM BY-PRODUCT) ON OR AROUND THE TB THROTTLE VALVE AND BORE.ODI CONCLUDES THAT THE TB PERFORMS IN A DEFECTIVE MANNER AFTER ANALYZING GM?S DATA SUBMISSIONS, AND TEST DATA COLLECTED BY THE VEHICLE RESEARCH AND TEST CENTER (VRTC).FIFTY-NINE CRASHES ARE ALLEGED TO HAVE OCCURRED AS A RESULT OF GM?S TB DEFECT.THE MAJORITY OF THE CRASHES INVOLVE A SINGLE VEHICLE, ENGAGING IN A CLOSE QUARTER VEHICLE MANEUVER (OR LOW SPEED), AND CAUSING ONLY MINOR PROPERTY DAMAGE.FOUR OUT OF THE FIFTY-NINE CRASHES INVOLVE INJURY, AND THOSE INJURIES WERE MINOR.ALTHOUGH GM?S TB IS DEFECTIVE, BASED ON THE EVIDENCE GATHERED, ODI HAS FOUND THAT THE ACCELERATOR PEDAL FORCE REQUIRED TO OPEN A STUCK THROTTLE VALVE IS NEGLIGIBLE, AND THE THROTTLE VALVE DOES NOT STICK IN THE OPEN POSITION.THEREFORE THIS ENGINEERING ANALYSIS (EA02-015) WILL BE CLOSED AT THIS TIME.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.FOR A DETAILED DISCUSSION OF THE TB COMPONENT AND TESTING, PLEASE SEE THE ATTACHED REPORT.