Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2002 Chevrolet Suburban 2500 owners, lightly cleaned up (personal details are redacted by NHTSA).
I have had several incidents in two weeks that nearly caused serious accidents. I would be driving at various speeds, slow and interstate driving, where the engine would suddenly lose all power and the battery light would come on. I would have to struggle to have the vehicle glide to the service lane without causing an accident. These happened all times of day and all weather conditions and caused hazardous close calls. The vehicle was through diagnostic testing by an independent mechanic found to have a defective crank position sensor. Attached for your information is a copy of the invoice which includes the diagnosis and repairs required. Reviewing NHTSA complaints this is a serious problem that appears to have happened many times in the past which needs to have a NHTSA investigation and recall. …
Tl* the contact owns a 2002 Chevrolet Suburban 2500. The contact stated that while driving 50 MPH, the vehicle stalled without warning and the brakes would pulsate and increase stopping distance. The VIN was not included in NHTSA campaign numbers: 07V521000 (engine and engine cooling) and 05V379000 (service brakes, hydraulic). The vehicle was taken to a dealer, who replaced the crank shaft sensor. The vehicle was not repaired for the brake failure. The failure mileage was 113,204. Updated 6/8/15 updated 10/2/2017
The engine stops running while driving or sitting at a stop sign without warning. Has happened at highway speeds, city driving speeds and while at a stop sign. Same problem as described in recall id: 07V521000. The dealer says my vehicle isn't covered in this recall. Why?
While driving 60 MPH under normal conditions on the interstate, I experienced full power loss. Without warning, the engine shut down and could not be restarted in neutral. Engine turned, just didn't fire. No sputter, no dash lights, just an instant shut down. I pulled the vehicle to the side of the roadway, put it in park and it started right up. Fortunately, this experience was on an not so crowded and straight section of the highway. I fear this could happen in a turn, in an intersection, or any situation where the lack of power steering could lead to an accident. This issue is the latest in a few related. What started a couple months ago as intermittent failed engine starts, has progressed into intermittent engine stalls. Initial problems were start related. The vehicle would make a normal starting sound, but just not fire. It would then start normally on the second or third attempt. …
After so long ignoring the smell in my cab, I decided to get it checked out at benny's exhaust in bristol, tn, and found that exhaust manifold head bolts broke off on both sides of engine. 1st bolt initially then second bolt next to it broke as well. No work has been done to motor or aftermarket parts added that would affect this part and create failure. Exhaust gas enters the underhood area sometime can be smelled inside passenger cab area. The exhaust makes a black plume up side of motor on both sides. This vehicle can not be registered in any state that has emissions testing, because it will not pass. I am forced to register it to non-testing states. Why isn't there a recall on this matter. It appears that this affects all years. What is wrong with GM, why won't they take care of this matter. …
A loud rattling noise was coming from under the hood and the had no A/C. After looking under hood, found the belt had split in two. I replaced the A/C belt on a 2002 Chevy Suburban and after doing this, noticed the belt tensioner was rattling a great deal so replaced it. When I received the belt tensioner from the parts store, enclosed was a warning/alert message to refer to GM tbs # 03-01-38-019a after reviewing this information, I don't understand why the customer should have to pay to replace the A/C compressor when they know it is a default on 17 vehicles from the years 2002 to 2004. I feel this should be Chevy and GM's responsibility as I now will need to pay well over $1000.00 to fix something that was a known problem, yet nothing was done about it. …
I drive a 2002 Chevrolet Suburban. Frequently, while I was driving and with no warning the vehicle just shuts off. When the vehicle shut off, it did not have power brakes or power steering. After stopping and turning the key off for a couple of minutes I could start up the vehicle and continue driving. This situation first started last fall. I took the vehicle to a local garage which could find any problem. The vehicle continued to experience these unpredictable shut offs ,and I took vehicle to the Chevrolet dealer for diagnosis and repair. The dealer could not duplicate the problem. The truck continued to shut off on the highway and in the city at highway and city speeds, while slowing down and while accelerating. This was a dangerous situation as it hds shut off while towing a trailer. The shut offs did not correlate with weather, time of day, useage, temperature, or speed. …
Vehicle would stall while driving without warning at all different speeds including highway speeds. Vehicle would sometimes stall 3 times per day, and sometimes not at all in a day. Loss of power steering and power brakes resulted which sometimes presented a challenge to safely get the vehicle off the highway or roadway while coasting to a stop. Stalls occured several times while towing a 5000 pound boat and also occured while towing a 9000 pound camper trailer. Two dealers looked at the vehicle and reported finding no cause for the stalling. I found an automotive internet discussion forum where many other people reported the same problem with the 8.1l engine. Many of these people reported that the crankshaft position sensor was the cause, and that replacing the crankshaft position sensor would fix the problem. …
Tl* the contact owns a 2002 Chevrolet Suburban 2500. The contact was driving approximately 45 MPH when the engine stalled, followed by the battery warning light illumination. The failure occurred eight more times. The vehicle was taken to the dealer who was unable to locate a problem. In addition, the vehicle was taken to an independent mechanic for a diagnostic testing which detected a trouble code with the crank position sensor. The vehicle was repaired. There was a recall related to the defect under NHTSA campaign id number 07V521000 (engine and engine cooling). The contact notified the dealer concerning the recall. The manufacturer was not made aware of the problem. The approximate failure mileage was 70,000. Updated 09/21/11 the consumer stated after waiting 15-30 seconds, the engine would start immediately and run smoothly. Updated 10/26/11
I have a 2002 Chevrolet Suburban 2500 4 wd with an 8.1 liter engine with 67,000 miles on it. It has stalled out 5 times over the last 6 months, nearly causing a serious crash on the second to last one on interstate route 80 outside of sparta, new jersey. The engine just stops and I have no control over the vehicle. I have taken it to two mechanics who have not been able to repair it. I am afraid to drive the vehicle. What should I do and where should I go to get this fixed. It is a life safety issue not only for me, but my family and horses when we haul horses for our equestrian activities. Can you imagine the disaster this would be with people and horses on the highway if the vehicle stops dead!!??
Engine complaints in other Suburban 2500 years
Frequently asked questions
How common are engine problems on the 2002 Chevrolet Suburban 2500?
NHTSA has 22 complaints about the engine & cooling of the 2002 Chevrolet Suburban 2500, 67% of the model year's 33 complaints. The component named most often is engine (4 mentions).
Is there a recall for 2002 Chevrolet Suburban 2500 engine problems?
No. NHTSA lists no engine & cooling recall for the 2002 Chevrolet Suburban 2500. 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 Suburban 2500 engine problems start?
Half of the complaints with a recorded mileage happened before about 76,000 miles, and 5% before 25,000 miles.
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.