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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.

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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

Electrical System complaints

10 reports
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151,000 miles · Sep 29, 2014
Electrical SystemService BrakesSteering

WHILE TOWING A 7000 LB 5TH WHEEL TRAILER THE ELECTRICAL PLUG BETWEEN THE VEHICLE AND TRAILER BECAME PARTIALLY DISLODGED AND AFFECTED THE VEHICLE ELECTRICAL SYSTEM WHICH MADE THE GAUGE NEEDLES GO HAYWIRE INCLUDING THE TACHOMETER. ENGINE STALLED WITH RESULTANT LOSS OF POWER STEERING AND BRAKES. LUCKILY WAS ABLE TO PULL INTO PARKIN…

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WHILE TOWING A 7000 LB 5TH WHEEL TRAILER THE ELECTRICAL PLUG BETWEEN THE VEHICLE AND TRAILER BECAME PARTIALLY DISLODGED AND AFFECTED THE VEHICLE ELECTRICAL SYSTEM WHICH MADE THE GAUGE NEEDLES GO HAYWIRE INCLUDING THE TACHOMETER. ENGINE STALLED WITH RESULTANT LOSS OF POWER STEERING AND BRAKES. LUCKILY WAS ABLE TO PULL INTO PARKING LOT AND STOP USING TRAILER BRAKES. REINSERTED PLUG FULLY INTO SOCKET AND HAVE NOT HAD A PROBLEM SINCE. *TR

NHTSA ODI #10639789

Mileage unknown · Apr 6, 2014
Electrical SystemStructure

I BELIEVE THAT I ALSO HAVE A PROBLEM WITH MY IGNITION AND FRONT PANEL. I CAN PULL MY KEY OUT IN ANY POSITION. EVERYTHING LIGHTS UP ON THE DASHBOARD AT ONE TIME OR ANOTHER. IT HAS CALLED MY VEHICLE TO STALL OR EVEN SHUT DOWN ALTOGETHER. I DON'T UNDERSTAND WHY MY VEHICLE HAS NOT BEEN RECALLED. I HAVE HAD IT IN SEVERAL TIMES B…

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I BELIEVE THAT I ALSO HAVE A PROBLEM WITH MY IGNITION AND FRONT PANEL. I CAN PULL MY KEY OUT IN ANY POSITION. EVERYTHING LIGHTS UP ON THE DASHBOARD AT ONE TIME OR ANOTHER. IT HAS CALLED MY VEHICLE TO STALL OR EVEN SHUT DOWN ALTOGETHER. I DON'T UNDERSTAND WHY MY VEHICLE HAS NOT BEEN RECALLED. I HAVE HAD IT IN SEVERAL TIMES BUT AM UNABLE TO FIND OUT WHAT THE CAUSE IS. PLEASE HELP ME. MY TRUCK SCARES ME SO MUCH, I'M AFRAID TO DRIVE IT, ESPECIALLY ON THE FREEWAY, OR ROADS THAT ARE BLACKED OUT FOR CELL PHONES, AND NO WAY TO GET HELP. *TR

NHTSA ODI #10577724

155,000 miles · Sep 15, 2010
Electrical SystemEquipmentVisibility

BLOWER MOTOR STOPPED WORKING LAST YEAR. I HAD A NEW BLOWER MOTOR INSTALLED AND THE REPLACEMENT STOPPED WORKING. WHEN I BROUGHT MY TRUCK TO BE REPAIRED FOR THE SECOND TIME, I WAS INFORMED THAT THERE IS A PROBLEM WITH THE WIRING/RESISTOR WHICH SUPPLIES POWER TO THE BLOWER MOTOR. APPARENTLY, THE MOTOR PULLS MORE POWER THAN THE W…

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BLOWER MOTOR STOPPED WORKING LAST YEAR. I HAD A NEW BLOWER MOTOR INSTALLED AND THE REPLACEMENT STOPPED WORKING. WHEN I BROUGHT MY TRUCK TO BE REPAIRED FOR THE SECOND TIME, I WAS INFORMED THAT THERE IS A PROBLEM WITH THE WIRING/RESISTOR WHICH SUPPLIES POWER TO THE BLOWER MOTOR. APPARENTLY, THE MOTOR PULLS MORE POWER THAN THE WIRING IS RATED FOR WHICH CAUSES IT TO HEAT UP AND BURN THE INSULATION OFF OF THE WIRING UNDER THE DASHBOARD. MY MECHANIC TOLD ME THAT I SHOULD CONSIDER MYSELF LUCKY THAT MY TRUCK DID NOT CATCH FIRE LIKE ANOTHER CUSTOMER'S TRUCK HE HAD RECENTLY REPAIRED FOR THE SAME REASON AS MINE HAD. I FEEL THAT I HAVE PAID FOR REPAIRS TWICE DUE TO DEFECTIVE GM PARTS. *TR

NHTSA ODI #10355756

95,000 miles · Aug 24, 2010
Electrical SystemEngine And Engine CoolingFire

ON 01/10/2010 AT 2:45 A.M. WE WERE AWAKENED BY A PASSER BY WHO NOTICED OUR TRUCK WAS ON FIRE. BY THE TIME THE FIRE DEPARTMENT WAS ABLE TO PUT THE FIRE OUT IT HAD COMPLETELY DESTROYED OUR TRUCK, OUR CAR ,OUR GRANDSONS TRUCK AND $66,000.00 DAMAGE TO THE HOUSE WE WERE RENTING. WE LOST OUR VEHICLES AND 90% OF EVERYTHING WE OWN. IT W…

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ON 01/10/2010 AT 2:45 A.M. WE WERE AWAKENED BY A PASSER BY WHO NOTICED OUR TRUCK WAS ON FIRE. BY THE TIME THE FIRE DEPARTMENT WAS ABLE TO PUT THE FIRE OUT IT HAD COMPLETELY DESTROYED OUR TRUCK, OUR CAR ,OUR GRANDSONS TRUCK AND $66,000.00 DAMAGE TO THE HOUSE WE WERE RENTING. WE LOST OUR VEHICLES AND 90% OF EVERYTHING WE OWN. IT WAS DETERMINED TO BE THE ENGINE BLOCK HEATER IN OUR 2002 CHEVY SILVERADO 2500 HD. WE HAVE BEEN IN CONTACT WITH GENERAL MOTORS. WE GAVE THEM ALL THE FIRE REPORTS FROM BOTH WEST VALLEY CITY FIRE DEPARTMENT AS WELL AS THE REPORT AND PICTURES PROVIDED BY THE INVESTIGATOR. THEY DO NOT CLAIM ANY RESPONSIBILITY FOR THE FIRE AND WILL NOT COMPENSATE US FOR OUR LOSS. *TR

NHTSA ODI #10351519

73,200 miles · Aug 4, 2010
Electrical SystemEngine And Engine Cooling

THE CAR WAS OPERATING NORMALLY AS I WAS LEAVING THE PARKING LOT AFTER SHOPPING. THE ENGINE WAS AT NORMAL OPERATING TEMPERATURE. THE ENGINE STALLED, LOST POWER BRAKES AND STEERING. THIS OCCURRED FIVE TIMES IN A PERIOD OF APPROXIMATELY ONE WEEK. THE ENGINE WOULD RESTART AFTER ONE MINUTE OR MORE. THERE WERE NO SES OR MIL INDICATION…

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THE CAR WAS OPERATING NORMALLY AS I WAS LEAVING THE PARKING LOT AFTER SHOPPING. THE ENGINE WAS AT NORMAL OPERATING TEMPERATURE. THE ENGINE STALLED, LOST POWER BRAKES AND STEERING. THIS OCCURRED FIVE TIMES IN A PERIOD OF APPROXIMATELY ONE WEEK. THE ENGINE WOULD RESTART AFTER ONE MINUTE OR MORE. THERE WERE NO SES OR MIL INDICATIONS OR DTC CODES. I GOOGLED THE FAILURE AND FOUND SEVERAL PEOPLE WITH SAME PROBLEM. I ALSO FOUND A NHTSA RECALL 06083 FOR A 2001 YEAR MY VEHICLE IS A 2002. I TOOK THE VEHICLE TO THE CHEVROLET DEALER AND HAD THE CRANKCASE POSITION SENSOR REPLACED AND THAT SOLVED THE PROBLEM. TO ELABORATE ON THE PROBLEM IT DID OCCUR WHILE I WAS DRIVING DOWN THE HIGHWAY AT 65 MILES PER HOUR. THAT IS VERY SCARY AND AS THIS IS A TRUCK I COULD HAVE BEEN TOWING MY BOAT. I DO HAVE THE DEFECTIVE PART. IT SEEMS TO ME THAT ALL THE DEFECTIVE PARTS WERE NOT REMOVED FROM INVENTORY OR THE SOLUTION TO THE PROBLEM WAS INADEQUATE. *TR

NHTSA ODI #10347346

138,000 miles · Jun 8, 2009
Electrical System

TL*THE CONTACT OWNS A 2002 CHEVROLET SILVERADO 2500 HD. INTERMITTENTLY, WHILE DRIVING VARIOUS SPEEDS, THE CONTACT NOTICED THAT THE BATTERY WARNING INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL. AFTERWARDS, THE VEHICLE STALLED. NORMALLY AFTER THE FAILURE OCCURS, THE VEHICLE IS ABLE TO BE RESTARTED. IN ADDITION, THE VEHICLE EX…

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TL*THE CONTACT OWNS A 2002 CHEVROLET SILVERADO 2500 HD. INTERMITTENTLY, WHILE DRIVING VARIOUS SPEEDS, THE CONTACT NOTICED THAT THE BATTERY WARNING INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL. AFTERWARDS, THE VEHICLE STALLED. NORMALLY AFTER THE FAILURE OCCURS, THE VEHICLE IS ABLE TO BE RESTARTED. IN ADDITION, THE VEHICLE EXHIBITED A NO-START CONDITION. THE CONTACT TOOK THE VEHICLE TO THE DEALER ON SEVERAL OCCASIONS AND THEY REPLACED THE ALTERNATOR, ON-BOARD ASSEMBLY IN THE COMPUTER SYSTEM, THROTTLE PLATE, AND REPROGRAMMED THE PCM. THE REMEDIES HAVE NOT CORRECTED THE FAILURES. THE FAILURE AND CURRENT MILEAGES WERE 138,000. UPDATED 07/24/09. *LJ

NHTSA ODI #10273096

133,533 miles · Apr 15, 2009
Electrical SystemFuel System, Other

I OWN A 2002 CHEVROLET SILVERADO 2500 HD, 8.1 LITER, V8. IN THE PAST 4 MONTHS, THE VEHICLE COMPLETELY WOULD LOSE POWER AND SHUT OFF. AFTER A FEW MINUTES, THE VEHICLE WOULD RESTART. IT DID NOT MATTER THE SPEED OF THE VEHICLE, NOR DISTANCE DRIVEN. THERE WAS NO DASH BOARD LIGHTS ON INDICATING ANY PROBLEMS. I STALLED SEVERAL TI…

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I OWN A 2002 CHEVROLET SILVERADO 2500 HD, 8.1 LITER, V8. IN THE PAST 4 MONTHS, THE VEHICLE COMPLETELY WOULD LOSE POWER AND SHUT OFF. AFTER A FEW MINUTES, THE VEHICLE WOULD RESTART. IT DID NOT MATTER THE SPEED OF THE VEHICLE, NOR DISTANCE DRIVEN. THERE WAS NO DASH BOARD LIGHTS ON INDICATING ANY PROBLEMS. I STALLED SEVERAL TIMES IN TRAFFIC, NEARLY MISSING/CAUSING ACCIDENTS. THE DEALER HAD VEHICLE FOR 3 DAYS AND SAID THERE WAS NOTHING ON DIAGNOSTIC SHOWING PROBLEMS. I REFUSED VEHICLE STATING I WAS NOT GOING TO ENDANGER MYSELF OR FAMILY TILL RESOLVED. IT WAS DETERMINED, AFTER THE GM BLOG AND PERSONAL INTERNET SEARCH OF THIS VEHICLE COMPLAINTS, THE CRANKSHAFT POSITION SENSOR WAS BAD. THE DEALER REPLACED FOR A CHARGE OF $288.38 PARTS/LABOR AT MY EXPENSE. THIS VEHICLE NEEDS A RECALL FOR THIS PART AND SOMEONE IS GOING TO BE SERIOUSLY HURT, ESPECIALLY WHEN THERE IS NO INDICATION OF A PROBLEM SHOWING. CASE #71-71437694 FILED WITH CHEVROLET AT 1-800-630-2438. *TR

NHTSA ODI #10265436

50,000 miles · Jul 19, 2007
Electrical System

MY 2002 CHEVY 2500 HD SILVERADO WITH 8.1 ENGINE QUITS RUNNING WHILE DRIVING. DOES NOT MATTER WHAT SPEED I'M GOING, IT JUST STOPS RUNNING. AFTER I PULL OVER PUT TRUCK IN PARK, TURN KEY OFF FOR A FEW MINUTES IT WILL USUALLY START UP. *JB

NHTSA ODI #10196894

30,889 miles · Sep 5, 2005
Electrical SystemEngine And Engine Cooling

2002 CHEVROLET 2500HD W/ 8.1L GASOLINE ENGINE: THE FAILURE OF THE CRANKSHAFT POSITION SENSOR ON THESE ENGINES APPEARS TO BE A VERY COMMON PROBLEM. THIS SENSOR FAILED ON MY TRUCK AT ONLY 30K MILES! I KNOW OF TWO OTHER '02 TRUCKS W/ THIS ENGINE THAT ALSO HAD THE SENSOR FAIL AND MANY OTHERS HAVE BEEN DISCOVERED WHILE DOING RESEARCH…

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2002 CHEVROLET 2500HD W/ 8.1L GASOLINE ENGINE: THE FAILURE OF THE CRANKSHAFT POSITION SENSOR ON THESE ENGINES APPEARS TO BE A VERY COMMON PROBLEM. THIS SENSOR FAILED ON MY TRUCK AT ONLY 30K MILES! I KNOW OF TWO OTHER '02 TRUCKS W/ THIS ENGINE THAT ALSO HAD THE SENSOR FAIL AND MANY OTHERS HAVE BEEN DISCOVERED WHILE DOING RESEARCH ON THIS PROBLEM! THE SERIOUSNESS OF THE PROBLEM LIES IN THE FACT THAT THE TRUCK SUDDENLY STOPS RUNNING FOR NO REASON AND YOU LOSE ALL POWER FOR THE BRAKES AND STEERING. AT TIMES IT WILL RESTART WITHOUT ANY PROBLEMS ONCE YOU SHIFT TO NEUTRAL, BUT OTHER TIMES IT MAY NOT RESTART FOR A DAY OR MORE. THIS WAS A HUGE SAFETY ISSUE FOR ME SINCE I TOW A 10K LBS. FIFTH-WHEEL WITH THE TRUCK! MY TRUCK STOPPED RUNNING FOUR TIMES OVER THE COURSE OF TWO WEEKS AS A RESULT OF THIS PROBLEM. EVERYTIME WAS WHILE TRAVELING IN TRAFFIC, WITH ONLY ONE OF THE TIMES WHILE BEING STOPPED AT A LIGHT! MY TRUCK IS NO LONGER UNDER WARRANTY DUE TO THE TIME LIMIT OF 36 MONTHS EXPIRING. TO HAVE SUCH A PART FAIL WITH ONLY 30K MILES ON THE ENGINE IS OUTRAGEOUS. ONE OF THE OTHER TRUCKS I KNOW OF HAD THE SENSOR FAIL AROUND 55K MILES. SAME PROBLEM, IT WOULD JUST STOP IN TRAFFIC OR WHEN PULLING OUT OF A LIGHT OR STOPPED TURN. AGAIN, A HUGE SAFETY ISSUE!!! THE COSTS TO ME TO REPAIR MY TRUCK FOLLOW: AC DELCO REPLACEMENT CRANKSHAFT SENSOR - $69.26 TOW CHARGES TO TOW TO JOSEPH CHEVROLET, CINCINNATI, OH - $58.85 LABOR DUE TO THE ORIGINAL SENSOR BREAKING IN THE BLOCK! - $336.54 TOTAL COST TO REPLACE THE SENSOR AFTER ONLY 30K MILES! = $464.65 AGAIN, I HAVE TO REPEAT HOW LARGE A SAFETY ISSUE THIS IS ON THESE TRUCKS!!! THE ENGINE JUST STOPS FOR NO REASON AT ANY TIME, HIGHWAY, SLOW MOVING, STOPPED, ETC. IT MAY RESTART, BUT THEN AGAIN IT MAY NOT FOR MANY HOURS! THE TRUCKS WITH THESE ENGINES IN THEM ARE GENERALLY TOWING LARGE TRAILERS BEHIND THEM. THIS COMPOUNDS THE SAFETY ASPECT OF THE PROBLEM. *JB

NHTSA ODI #10135343

13,400 miles · Dec 2, 2003
Electrical SystemFire

VEHICLE WAS PARKED WHEN NEIGHBOR NOTICED SMOKE COMING OUT OF THE ENGINE AREA. CONSUMER USED FIRE EXTINGUISHER TO PUT OUT THE FIRE. *AK *PH

NHTSA ODI #10042807

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.