2002 GMC Sierra 3500

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.

TL* THE CONTACT OWNS A 2002 GMC SIERRA 3500. WHILE OPERATING THE VEHICLE, THE ODOR OF FUEL WAS NOTICEABLE INSIDE THE CABIN. UPON INSPECTION, THE CONTACT DISCOVERED FUEL HAD LEAKED FROM THE VEHICLE ONTO THE GROUND. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE FUEL INJECTORS NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 120,000.

NHTSA ID

10860980

Incident

Apr 15, 2016

Mileage

120,000 mi

THIS TRUCK HAS THE SAME PROBLEMS AS THE 2007 MODEL. THE IGNITION SWITCH, PARKING BRAKE, AND FUEL LINES ALL HAVE ISSUES AS SIMILARLY DESCRIBED FOR THE 2007 MODEL. THE FUEL LINES ACTUALLY BROKE THROUGH CAUSING A LEAK OF THE DIESEL FUEL. THIS HAPPENED AFTER THE VEHICLE WAS DRIVEN A SHORT DISTANCE OF 15 MILES.

NHTSA ID

10787186

Incident

Mar 2, 2015

Mileage

101,000 mi

WHILE DRIVING DOWN A VERY BUSY STREET, THE ENGINE DIED. I LOST ALL MY POWER STEERING AND BRAKE. I WAS VERY LUCKY THAT I WAS NOT ON A VERY BUSY HIGHWAY. I HAD IT TOWED TO HEDRICK'S CHEVROLET IN CLOVIS CA. IT TOOK 2 DAYS FOR THEM TO CHECK IT OUT. THEY SAID WHEN THEY WENT TO BRING IT IN TO THE SHOP IT STARTED UP AND THEY COULD NOT FIND ANYTHING WRONG WITH IT. I PICKED THE TRUCK UP AND THE NEXT DAY IT DID THE SAME THING AGAIN. I CALLED THE DEALER AND THEY TOLD ME TO PRESS THE PUMP ON THE TOP OF THE FILTER HOUSING UNTIL I COULD NO LONGER PRESS IT. I DID THAT AND IT STARTED UP. BE CAME VERY OBVIOUS THAT THEY WERE AWARE THAT THE FUEL FILTER HOUSING WAS CAUSING THE INJECTION SYSTEM TO LOSE SUCTION I TOOK IT BACK TO THE DEALER AND THEY REPLACED THE FUEL FILTER HOUSING. I HAVE SINCE FOUND OUT THAT THIS FAILURE IS A COMMON FAILURE. EVIDENTLY THERE IS AN O RING IN THE HOUSING AND IT FAILS AND BASED ON FACT THAT THEIR SERVICE PERSON WAS ABLE TO TELL ME HOW TO START THE TRUCK, THEY NEW OF THESE FAILURES AND NEVER TOLD OWNERS ABOUT THIS. ...UPDATED 09/22/15 *BF UPDATED 12/9/2015 *JS

NHTSA ID

10731304

Incident

Jun 17, 2014

Mileage

85,118 mi

SLOWING DOWN TO A RED TRAFFIC LIGHT AND BRAKE PEDAL WENT TO THE FLOOR. TRIED TO PUMP BRAKE PEDAL TO GET MORE PRESSURE BUT DID NOT WORK. DROVE OFF ONTO SHOULDER AND GOT IT SLOWED DOWN . DRIVE VERY SLOW WITH HAZARD LIGHTS ON TO GET IT BACK TO MY HOUSE. I WAS ONLY ABOUT A MILE AWAY. GOT HOME AND LOOKED UNDERNEATH TO FIND BRAKE FLUID ALL OVER LEFT REAR WHEELS, FUEL TANK, LEFT REAR SHOCK AND DRIVE AXLE. CONTINUED TO LOOK AT ALL BRAKE LINES AND ALL OF THEM WERE CORRODED BAD. GETTING PRICES ON HAVING ALL BRAKE LINES REPLACED. *TR

NHTSA ID

10526003

Incident

Jul 19, 2013

Mileage

137,000 mi

I FIRST NOTICED THAT THE ANTI-LOCK BRAKES WERE ACTIVATING AT SLOW SPEEDS ( 5-10 MPH ) UNDER DRY ROAD CONDITIONS. THIS WAS PRIOR TO BRAKE LINE INCIDENT ON 4-14-2012 BUT I AM NOT SURE OF EXACT DATE. I RESEARCHED THE ANTI-LOCK BRAKES AND FOUND NHTSA ID CAMPAIGN #05V379000 ACTION # PE05020 BUT THIS DID NOT INCLUDE MY HOME STATE OF KENTUCKY. HOWEVER, I HAVE BEEN WORKING IN OHIO SINCE THE PURCHASE OF SAID VEHICLE 10-17-2001 TO CURRENT DATE 2-11-2013. ON 4-14-2012 I WAS PREPARING TO TAKE MY BOAT TO FUEL IT . WHILE CHECKING THE TRAILER LIGHTS I STEPPED ON THE BRAKE PEDAL AND IT WENT STRAIGHT TO THE FLOOR. I FOUND THAT THE BRAKE LINE TO THE REAR WHEELS HAD BURST IN HALF AND WAS SEVERELY CORRODED. UPON CLOSER INSPECTION I FOUND THAT ALL THE BRAKE LINES SHOWED SIGNS OF SEVERE CORROISION. ON 2-8-2013 I DISCOVERED THAT DIESEL FUEL WAS LEAKING NEAR THE FUEL TANK AND FUEL COOLER. IT WAS FOUND TO BE A CORRODED RETURN FUEL LINE BETWEEN THE COOLER AND THE FUEL TANK .AGAIN UPON CLOSER INSPECTION ALL FUEL LINES SHOW MODERATE TO SEVERE CORROISION. *TR

NHTSA ID

10497825

Incident

Apr 14, 2012

Mileage

154,163 mi

THIS MORNING I NOTICED THE BRAKE PEDAL TRAVELING DOWN FURTHER THAN NORMAL AND LITTLE TO NO STOPPING POWER. ONCE ARRIVING AT WORK I TRIED TO PUMP THE BRAKE PEDAL AND IT KEPT GOING TO THE FLOOR. UPON LOOKING UNDER THE TRUCK I DISCOVERED A PUDDLE OF BRAKE FLUID. AFTER FURTHER INSPECTION I FOUND ONE OF BRAKE LINES HAD RUSTED THROUGH AND BLOWN OUT IN FRONT OF THE ABS MODULE. THE GENERAL CONDITION OF ALL THE BRAKE LINES IN THIS AREA IS VERY RUSTY. I WILL LIKELY HAVE TO REPLACE ALL THE BRAKE LINES DUE TO THIS. *TR

NHTSA ID

10465361

Incident

Jul 12, 2012

TL* THE CONTACT OWNS A 2002 GMC SIERRA 3500. WHILE DRIVING APPROXIMATELY 65 MPH, THE VEHICLE BEGAN TO SMOKE AND LOSE POWER ABNORMALLY. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE FUEL FILTER WAS REPLACED. THE FAILURE RECURRED IN LESS THAN ONE YEAR. THE VEHICLE WAS TAKEN BACK TO THE DEALER AND THE CONTACT WAS ADVISED THAT THERE WERE THREE DEFECTIVE FUEL INJECTORS THAT WOULD NEED REPLACING. THE CONTACT STATED THAT THE VEHICLE WAS PREVIOUSLY REPAIRED UNDER NHTSA CAMPAIGN ID NUMBER: 06E043000 (FUEL SYSTEM, GASOLINE) YET THE REPAIR DID NOT REMEDY THE FAILURE. THE VIN WAS UNAVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 80,000 AND THE CURRENT MILEAGE WAS 82,828.

NHTSA ID

10377169

Incident

Feb 1, 2010

Mileage

80,000 mi

TL*THE CONTACT OWNS A 2002 GMC SIERRA 3500. WHILE DRIVING 15 MPH, THE ANTILOCK BRAKE SYSTEM BEGAN TO ACTIVATE IN NORMAL WEATHER CONDITIONS. AS A RESULT, THE BRAKES BEGAN TO TREMBLE. THE VEHICLE WAS TAKEN TO THE DEALER, BUT THEY WERE UNABLE TO DETERMINE THE CAUSE OF THE FAILURE. THE VEHICLE WAS TAKEN TO A LOCAL REPAIR SHOP AND A TECHNICIAN STATED THAT THERE WAS CORROSION OF THE WHEEL SPEED SENSOR, WHICH CAUSED THE ABS TO ACTIVATE. NO REPAIRS HAVE BEEN MADE. THE MANUFACTURER STATED THAT THE VIN WAS NOT INCLUDED IN THE RECALL AND NO REIMBURSEMENT WOULD BE PROVIDED. THE NHTSA CAMPAIGN ID NUMBER WAS UNKNOWN. THE FAILURE MILEAGE WAS 49,100 AND CURRENT MILEAGE WAS 50,289.

NHTSA ID

10256455

Incident

Sep 28, 2008

Mileage

49,100 mi

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.

This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.

Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected modules (with some exceptions). The updating of modules is completed in parallel instead of the technician needing to update one module at a time. This allows a more streamlined approach for dealers and customers.

GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the dealers to be more careful not to damage the transmissions during removal and to package the core properly for return.

This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up.