Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2002 Chevrolet Silverado 2500 owners, lightly cleaned up (personal details are redacted by NHTSA).
As I was driving at 75 MPH, the indicator light said, engine overheated. I then noticed white smoke coming from the hood. The white smoke turned black. I pulled over to the side of the road and before I could shut the engine off, the engine shut off on its own. Fire began coming up where the windshield wipers are located and proceeded through the dashboard. I tried to unlatch my seat belt but it would not release. After several tries it released. I attempted to open the door; however, I had the same problem. The door did not open. After bumping the door forcibly many times, it also came open. Mind you, all the while the flames are coming inside the cab. I called 911 and the county fire department was dispatched, but not before it was fully engulfed in flames. The vehicle was well maintained. I want to know what steps to take to prevent this from ever happening again?
My ABS speed sensor got sheared by back of my front drivers side tire in which I have seen on multiple sights a defect that was deemed a recall for being poorly set up on the assembly line. Secondly, ive spent thousands and looking online for a vary serious issue ive been having with my vehicle due to intermediate stalling, backfiring, and vehicle dieing due to what has finally been found to be the infamous crankshaft sensor. Replaced my computer, all 02 sensors, EGR valve exc... Than upon looking and researching, I find it was a major one on recall as well for failing all the time. I just feel if these are factory errors and been on the recall, and my woman who travels with me that is paralyzed due to an accident, I should be entitiled to the recalls giving they were known flaws on the asssembly line and a danger to others. …
My complaint is more of a question. How can a recall have a cutoff deadline, especially when the item recalled May or May not be bad? There was a recall on my injectors and I never new it till they went bad and I took it to dealer to fix and they said injectors had been recalled but recall expired. Then, 13 months after having them replaced, 3 go bad and ya'll only offer a 1 year warranty when you replace them, how convenient. You have an expiration on a recall.
My 2002 Chevy Silverado with duramax diesel engine broke down while on a trip from michigan to florida. The diesel injector casing failed causing the crankcase to overfill with diesel fuel then caused oil and diesel fuel mix to come out of the engine while traveling down the road covering the underside of the vehicle and roadway as well as vehicles directly behind me. The GM dealer in georgia stated we were in by mileage but out of the extended 7 year 200000 mile injector warranty by 1year and 4 days and the cost would be $6250 to replace 8 injectors. They offered a 10% discount off that repair. Subsequent calls to GM customer assistance were made to no end (they stated the 10% discount was their best offer). …
I have a 2002 Chevrolet Silverado 2500hd lt ext. Cab lb7 duramax 5 speed allison transmission, it has 114000 miles on it. This truck has been serviced as directed since new. The truck started using lots of fuel, at an idle it serged between 700 & 900 RPM's, and oil started blowing out the blowby tube. I have just found out that 3 fuel injectors are leaking fuel, with a possible head gasket leak,filling my crankcase with diesel, causing oil to blow out all over the truck, road and whatever else it can Land on. While investigating what to do, to fix the truck I've found 3 other people I know that have duramax's, and they are going through the same problems. It's going to take me a year to save the money I need to fix this truck. I'm even going to do the work myself. In my opinion GM should be ashamed. They should at leased pay for the parts. …
After arriving at my destination at 9 pm as I exited truck , I smelled deisel fuel. Took a flashlight and looked under truck and saw diesel dripping off frame rail on drivers side of vehicle. I spent the next 5 hours affecting a temporary fix on the metal fuel line to stop the leak overnight. As I ran my thumb along the fuel line in an effort to isolate the exact spot of the leak, the leak went from a drip, drip, etc to a pinhole stream. There was absolutely no dent from external contact of any kind. I am the original owner of this vehicle. It has been well maintained and we do not live in an area of much winter weather ( salt corrosion ). The next day after a 3 mile walk to purchase some hose repair clamps, I improvised a sturdy patch which allowed me to drive the vehicle home more than 2 hours away. I have contacted Chevrolet and will be taking the truck to a dealer Monday 7/24. …
I own a 2002 chev k2500hd. I have had several problems, but was unaware of this site to report these problems until now. First, the dryer switch on the ac went bad @ 34K. Second,@ 65K I had to replace the front left wheel hub assembly as talked about in one of the other complaints I read. Third, @ 95K my transfer case developed a leak and I lost all the fluid. A Chevrolet mechanic showed me a transfer case that had gone bad due to the same problem and had been used in 4wd w/out fluid in it. Another Chevrolet mechanic told me he had seen several of these and that "jb weld is your friend". So I patched the hole, and 10K later it developed a second leak in a similar location and also about this same time an electrical part (about $550) went out for my 4wd. Now at 130K it has developed a third leak! …
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. …
We have a 2500 hd also with failed injectors. We were not injured nor killed. However, oil and diesel blew out on roadway and on the engine of truck. I do not know if this caused an accident with the vehicle behind me or not. How many accidents could have happened and no one realized it was from the oil of our truck. Further more Chevy knows this is a problem. So how many people have to get hurt or die before they take care of the problem. Of everyone I have talked to only one person was under warranty and they made it by 14 days. Chevy has a problem and needs to fix it, and not with an extended warranty. This is my first Chevy and will be my last. Maybe that is why Chevy needed bail out money
Tl* the contact owns a 2002 Chevrolet Silverado 2500 hd. The contact stated that the vehicle suddenly stalled while parked. The contact inspected the vehicle and noticed a failure with the fuel injector pump. The contact pumped air out of the fuel injectors and restarted the vehicle. The vehicle was taken to a dealer for diagnostics where the technician stated that the fuel injector and fuel injector pump had to be replaced. The vehicle was not repaired. The contact stated prior to having ownership of the vehicle, the fuel injectors were replaced under an extended warranty. The approximate failure mileage was 180,000. The VIN was not available.
Fuel System complaints in other Silverado 2500 years
Frequently asked questions
How common are fuel system problems on the 2002 Chevrolet Silverado 2500?
NHTSA has 30 complaints about the fuel & propulsion system of the 2002 Chevrolet Silverado 2500, 9% of the model year's 351 complaints. The component named most often is fuel injection system (4 mentions).
Is there a recall for 2002 Chevrolet Silverado 2500 fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2002 Chevrolet Silverado 2500, though it has 1 recall for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2002 Chevrolet Silverado 2500 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 125,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 0 injuries to fuel & propulsion system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.