2002 GMC Sierra 3500: what breaks, and at what mileage
What breaks on the 2002 GMC Sierra 3500
On the 2002 GMC Sierra 3500, the failure owners report most often is fuel tank, filler or EVAP failure, and the reports cluster around 155,000 miles. Across every failure mode on this year, half the dated reports were filed before 100,000 miles. Overall it scores 61 out of 100, high risk for a 2002.
High risk for a 2002 — 292nd riskiest of the 328 2002 vehicles we can rate. 29 owner reports; fleet size estimated from this year's own recall paperwork.
The failures owners actually file about
Owners have reported 12 named failure modes on the 2002 GMC Sierra 3500, and the three most-reported carry 48% of everything filed.
Fuel tank, filler or EVAP failure leads with 8 reports, about 1.6 per 1,000 vehicles and with the middle half of reports between 137k to 155,000 miles.
Ignition switch, key fob or immobilizer failure follows with 3 reports, median 100,000 miles.
Parking brake failure follows with 3 reports, median 40,000 miles.
By system, the reports fall mostly into fuel (11), brakes (6) and electrical (3).
When these failures get reported
22 of the reports on the 2002 GMC Sierra 3500 came with an odometer reading, and half of those were filed before 100,000 miles.
Cumulatively, 23% by 50,000 miles, 45% by 100,000 miles and 77% by 150,000 miles of the dated reports had been filed.
The busiest stretch is between 150,000 and 160,000 miles, which alone holds 23% of the dated reports.
14% of the dated reports were filed below 36,000 miles.
Tick median reported mileage Solid middle half of reports Faint 10th to 90th percentile Colour how bad the failure is when it happens
How reports accumulate
Every report with an odometer reading, cumulative, from 0 to 200,000 miles. A curve that climbs early is a car with early problems, whatever its total.
- Line share of reports filed by that mileage
- Dashed the median reported mileage
Severity, and what it costs
Across the named modes, 1 mentions a crash and 1 a fire. Those are the words owners used in their own complaints, and NHTSA does not verify them, but they are the closest thing in this data to a measure of what a failure actually did.
The average severity weight across every report on this year is 4.00, where a stalled engine or a failed airbag weighs many times more than a rattling trim panel, and a figure this high means the reports are dominated by failures with safety consequences rather than annoyances. The weighting is set out in full on the methodology page.
What the top failures cost to put right, as editorial estimates for an independent US shop rather than figures from NHTSA: fuel tank, filler or EVAP failure at $250–$1,800, ignition switch, key fob or immobilizer failure at $250–$1,500, parking brake failure at $250–$1,300 and ABS module or sensor failure at $500–$2,400. Dealer labour, a seized bolt or a part that is no longer made can push any of these past the top of its range.
7% of the reports on this year sit in the engine, transmission, drivetrain or cooling systems — the four where a repair bill is usually four figures.
Every reported failure mode
| Failure mode | System | Reports | With reading | 25th | Median | 75th | Per 1,000 | Typical repair | Severity |
|---|---|---|---|---|---|---|---|---|---|
| Fuel tank, filler or EVAP failure | fuel | 8 | 8 | 137k | 154k | 154k | 1.6 | $250–$1,800 | Moderate |
| Ignition switch, key fob or immobilizer failure | electrical | 3 | 3 | — | 101k | — | 0.6 | $250–$1,500 | High |
| Parking brake failure | brakes | 3 | 2 | — | 40k | — | 0.6 | $250–$1,300 | Moderate |
| ABS module or sensor failure | brakes | 2 | 1 | — | 49k | — | 0.4 | $500–$2,400 | High |
| Other engine problem | engine | 2 | 1 | — | 120k | — | 0.4 | $300–$4,000 | High |
| Other fuel system problem | fuel | 2 | 2 | — | 83k | — | 0.4 | $300–$2,200 | High |
| Other suspension problem | suspension | 2 | 0 | — | — | — | 0.4 | $350–$2,000 | Moderate |
| Fuel leak or fuel odor | fuel | 1 | 0 | — | — | — | 0.2 | $300–$2,500 | Critical |
| Tire blowout or tread separation | wheels | 1 | 1 | — | 30k | — | 0.2 | $200–$1,500 | Critical |
| Other brake problem | brakes | 1 | 1 | — | 42k | — | 0.2 | $300–$1,800 | High |
| Other wheel or tire problem | wheels | 1 | 1 | — | 89k | — | 0.2 | $200–$1,500 | High |
| Other visibility problem | glass | 1 | 0 | — | — | — | 0.2 | $150–$1,400 | Moderate |
| Unclassified problem | other | 2 | 2 | — | 53k | — | 0.4 | — | Moderate |
Rate per 1,000 uses a fleet-size estimate derived from recall paperwork for this exact model year. It is a lower bound. Repair costs are typical independent-shop ranges for the failure, not figures from these reports.
How often, against how many were built
Scaled by an estimate of how many of these cars exist, the 2002 GMC Sierra 3500 draws about 6.0 per 1,000 vehicles, which puts it in the 84th percentile of complaint rates among 2002 vehicles we can rate.
That denominator is the weakest number on the page and it is fair to say so plainly. Rate per 1,000 uses a fleet-size estimate derived from recall paperwork for this exact model year. It is a lower bound.
The working figure is 4,857 vehicles. If the true number is twice that, every rate on this page is half what it says; the ranking against other 2002 vehicles, which is what the risk score uses, is far more robust than the rate itself.
What owners wrote
Verbatim from NHTSA complaint narratives, trimmed for length. The odometer reading is the one the owner gave.
Fuel tank, filler or EVAP failure
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
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
Ignition switch, key fob or immobilizer failure
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.
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.
Parking brake failure
Dealership informed the consumer that the emergency parking brake wore out. This could potentially cause the vehicle to roll back/forward on a incline without warning. Dealership was not able to resolve the problem. *ak retainer on emergency brake failed. *la
This complaint is regarding NHTSA id # 05v161000 and gm recall # 05042. The above is for a defect in the parking brake which causes premature wear. The recall only applies to manual shift transmissions. I have this same problem but have an automatic transmission. I believe this recall should also apply to my vehicle since a parking brake is also installed on my vehicle and it is also defective. If a parking brake is not needed on my vehicle for safety than why is one installed? *jb
Recalls on the 2002 model year
NHTSA has issued 3 recall campaigns covering the 2002 GMC Sierra 3500, affecting an estimated 5,279 vehicles. A recall is a different kind of evidence from a complaint: it is the regulator and the manufacturer agreeing that something has to be fixed, and the fix is free for as long as the car exists.
The campaigns cover fuel system, gasoline, equipment adaptive/mobility and interior lighting. Whether the work was actually done on the car in front of you is a question only the VIN can answer, and the manufacturer or NHTSA will answer it free.
One caution about reading these together: a recall usually raises the complaint count for the same part, because owners who read about it go and file. The mileages stay informative; the counts get noisy.
FUEL SYSTEM, GASOLINE
88,303 vehicles 2006-05-19- Defect
- Certain replacement fuel filters, fram brand name p/n g3727, with date codes x52911 through x60801 sequentially or x600141 and a mexico country or origin marking on the fuel filter housing manufactured from october 18, 2005, through march 21, 2006, sold for use on the vehicles listed above and on certain school buses. (to see the school bus engine sizes, click on "document search" and then "bus applications"). The connector on the fuel filter was not manufactured to honeywell's specification. As a result, the o-ring may not seat correctly on the fuel line.
- Consequence
- This condition may cause an inadequate seal at the connection, potentially leading to a fuel leak. In the presence of an ignition source, a fire could occur.
- Remedy
- Honeywell will notify owners and replace the fuel filters free of charge. The recall began on october 18, 2006. Owners may contact fram customer service at 1-800-890-2075 (option 1).
EQUIPMENT ADAPTIVE/MOBILITY
1,660 vehicles 2004-11-26- Defect
- On certain vans equipped with sure-lok wheelchair securement systems, the sprocket teeth of the retractor assembly is out of alignment.
- Consequence
- In the event of a vehicle crash, the wheelchair may not be adequately secured possibly resulting in injuries to a wheelchair occupant.
- Remedy
- Dealers will inspect and replace the wheelchair securement retractors as necessary. Sure-lok will handle the repairs for this campaign. Owners should contact sure-lock at 1-908-231-1804 or mobilityworks at 1-800-769-8267.
INTERIOR LIGHTING
38,863 vehicles 2001-06-26- Defect
- 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
- 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.
Recall work is free at a franchised dealer regardless of the car's age. Check the VIN at nhtsa.gov/recalls before assuming it was done.
How it ranks in the 2002 field
The score at the top of the page, placed among its peers. The zones are the same thresholds the scorer applies, read out of the scorer itself, so the picture and the band word cannot disagree.
Scores are ranked within the model year, never across years, because an older car has had longer to accumulate reports.
- Left fewer and less serious reports
- Right more, or worse
- Marker this vehicle
How 2002 compares with the other years
High risk for a 2002 — 292nd riskiest of the 328 2002 vehicles we can rate. Because the ranking is against the same model year only, age cancels out of it.
Across the 23 model years of this car that carry enough reports to score, 2002 comes out best at 61 and 2000 worst at 77, with 2002 itself at 61.
No other year of this model scores meaningfully better than 2002, so if this generation is what you want, the year is not the lever.
Within the 1996–2002 generation specifically, 2002 is the strongest year at 61 and 2000 the weakest at 77.
Scores compare each year against other cars of the same model year, so a low number on an older car is a real result and not an artefact of age.
Shorter is better. Years with too few reports to score are shown without a bar rather than as a zero, because no data is not good news.
Within the 1996-2002 generation, 2002 GMC Sierra 3500 scores best at 61 and 2000 GMC Sierra 3500 worst at 77.
What the numbers say to check
The mileages below are where the first quarter of reports for each mode had already been filed, which makes them the point at which a fault is worth looking for rather than the point at which it happens: fuel tank, filler or EVAP failure from about 137k.
On a 2002 GMC Sierra 3500 with more miles than that on it, the useful question to put to a seller or a mechanic is whether fuel tank, filler or EVAP failure has been dealt with, and if so with what parts and at whose expense. A car that has already had the repair is in a different position from one that has not.
Treat it as where to point the inspection, not as a prediction. A well-maintained example can sail past every mileage on this page, and a neglected one can fail well before the first of them.
The limits of complaint data
29 owner reports; fleet size estimated from this year's own recall paperwork. Every count on this page is therefore a floor: it is the number of owners who went to the trouble of filing with a federal agency, which is a small and self-selected fraction of the owners who had the fault.
Of those 29 reports, 22 carried an odometer reading, so the mileages here describe 76% of the sample rather than all of it. Owners also round: readings pile up on multiples of ten thousand, which is why this site publishes "about 90,000 miles" and not "91,438".
The failure modes are assigned by software reading the owner's own words, which is accurate in bulk and wrong in individual cases. A mode with a handful of reports may contain a misfiled one.
And nothing here predicts what one car will do. These are other people's complaints, filed years apart, on cars maintained by strangers. Read the page as a map of where this model year has previously gone wrong, then have the specific car in front of you inspected.
Questions this page answers
What are the most common problems with the 2002 GMC Sierra 3500?
The most-reported failures are fuel tank, filler or evap failure (8 reports, median 155,000 miles), ignition switch, key fob or immobilizer failure (3 reports, median 100,000 miles) and parking brake failure (3 reports, median 40,000 miles). Counts come from owner complaints filed with NHTSA, which are voluntary, so they show what owners bothered to report rather than every fault that occurred.
At what mileage do 2002 GMC Sierra 3500 problems start?
Fuel tank, filler or evap failure is the earliest failure mode to show up, with a median reported mileage of 155,000 miles and a quarter of reports before 135,000 miles. Across all failure modes on this year, the median report sits at 100,000 miles.
Is the 2002 GMC Sierra 3500 reliable?
It scores 61 out of 100 on our risk index, which is high — 292nd riskiest of the 328 2002 vehicles we can rate. The score is a comparison against other 2002 vehicles, not a prediction about any individual car, and it is built from complaint rates, severity and how early failures appear.
Which year of the GMC Sierra 3500 is best?
Within the 1996–2002 generation, 2002 scores best at 61 out of 100 and 2000 worst at 77. Same body, same engines, different luck.
Where this comes from. Every figure above is computed from NHTSA owner complaints and recall records for this exact make, model and year. Complaints are voluntary and self-selected, so treat counts as a floor. The methodology page writes out each formula, and the same numbers are available as JSON.
What breaks at my mileage Compare with another car
Source Owner complaints and recall records published by the US National Highway Traffic Safety Administration, model years 1996–2027 Figures rebuilt Published by AtWhatMileage How every figure is computed