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 Trailblazer EXT owners, lightly cleaned up (personal details are redacted by NHTSA).
There is rust all over the inside of my engine, two exhaust manifold bolts rusted off and I had an exhaust leak. I had to have it fixed so I took it into a Chevrolet dealer. While it was there they told me that the gas tank had a crack in it and had to be replaced, at a cost of over 700.00 dollars. I can't afford to have the manifold and tank fixed. Now I am faced with either exhaust leaking or gas leaking. They said the gas tank was cracked at the neck. I called general motors to state that I thought it was a manufacturers defect. GM called the dealer and they told them that the vehicle was in good shape and that there was no sign of misuse or neglect. GM called me back and stated that the crack was due to the age of the vehicle and wear and tear. I have never heard of a vehicle gas tank cracking for no reason unless there was a defect in the gas tank itself. …
After refilling fuel tank full of gasoline and driving until ~80% full, I smelled fuel vapors coming from the vehicle when standing outside. Outside temperature was ~70 f. After the next trip the vehicle MIL came on. Codes were related to EVAP leak p0442. Dealer replaced fuel tank and filler neck tube, cracked. Almost 1 year prior GM issued a notice that this issue might occur and would be covered at GM's expense. I recalled that I had received a letter regarding a MIL light that might appear. Dealer repaired vehicle under this letter / warranty. Vehicle had ~80K miles. Driven daily in 4 season area.
Check engine light came on my 2002 Chevrolet Trailblazer (86,000 miles). Team Chevrolet analyzed and advised the gas tank is cracked. This same problem occurred at 12,000 miles but was repaired for free as vehicle was under warranty and there was an alert issued for this problem. However, the alert "policy" ran out at 70,000 miles so the dealership, nor GM will cover the estimated expenses of $850. I protested that this was a known and repeated problem and a fire/safety issue but they are not willing to assist in any way.
Smell of gas inside and outside of the vehicle after fill up. Took to dealership and notified them of an emission service bulletin #07099 regarding a fuel inlet check valve fracture. The dealerships assessment was that they found lines at top of sending unit rusted and fuel leaking out of lines, replaced sending unit. I do have the part they replaced and lines are rusted but see no holes where leaking occurred. Bill total was $816.78 (219.65 labor, 535.60 sending unit module, 15.30 seal.
After smelling gas fumes and having the "service engine soon" lamp illuminated, I took my 2002 Chevrolet Trailblazer EXT to my mechanic for service. The attachment from the fuel filler line and the gas tank was loose. He relayed that Chevy was having a lot of problems with this. After pursuing this with GM, I found a special policy # 05012. GM will fix the problem on vehicles with up to 70,000 miles. My vehicle has 72,000 miles. GM refuses to repair this defect.
The fuel tank on my vehicle has leaked or had an EVAP leak detected and had needed a replacement 4 times in 7 years of ownership. First replacement at 2288 miles on10/04/02, then 18474 miles on 10/17/03, then 34782 miles on 08/21/04 and 96121 miles on 01/21/09.the car dealership has completed the replacements each time and were previously covered by my extended warranty. It is now not covered by the warranty and needs replacing again at $1000 expense.
Chevy Trailblazer 2002 ltz - VIN [redacted] there is a crack in the connection between my gas tank and the filler pipe. Chevy told me that currently have a "special policy" #05012 which covers this flaw, however my car does not fall under that even though the symptoms are the same. How can I pursue this and get it fully covered. [redacted] updated 07/18/2012
Noticed strong fuel odor around the vehicle, found out a crack in the tank around the tube connecting the hose coming from the filler neck, quite dangerous it could lead to a fire, ask GM and the have a safety policy adjustment, but it expires when the car is 7 years old or 70000 miles, there are many many cases like this so this must be a recall issue at my point of view.
The check engine light came on. I took the 2002 Chevrolet Trailblazer to the dealer, who determined the gas tank leaked from the top of the tank where the gas entered. There was no way this could occur from wear and tear. This was a defect in the workmanship, product liability. It will cost approximately $800 for repairs.
I own 2002 Trailblazer and twice the fuel tank had broken around the filler neck letting fuel leak out. The problem is several other owners have had the same problem. The second time it broke I replaced it my self and I am sure it is a manufacturing defect. If a owner had this problem it could cause fire/explosion.
NHTSA investigations
Fuel tank leak
In June 2007, GM will expand its special policy to address fuel tank inlet check valve (icv) fractures on certain model year (my) trailblazer ext and GMC envoy xl vehicles.the expanded policy covers my 2002-2004 trailblazer ext, GMC envoy xl, and GMC envoy xuv vehicles and will extend for a period of 10 years or 150,000 miles (whichever comes first).GM will provide free repair of the fuel tank.
Fuel pump module leaks gasoline
Odi has received reports that the fuel pump module leaks fuel and or vapor underneath the vehicle.GM states, the failure mechanism is corrosion of the fuel pump module flange which May lead to a fuel leak.corrosion of the fuel pump module flange is the result of the vehicle operating in a corrosive environment.odi has upgraded this pe to engineering analysis (ea07-009) to further assess this issue.
Fuel pump module leaks gasoline
During the course of this ea investigation, odi observed that the majority of the complaints (88%) and warranty claims (94%) were reported for vehicles that are registered for use in the salt belt region of the us.this area includes 20 states in the northeast, mid atlantic and the midwest regions and the district of columbia.consumers in the salt belt region reported to odi that they could smell fuel vapors in their…
Fuel System complaints in other Trailblazer EXT years
Frequently asked questions
How common are fuel system problems on the 2002 Chevrolet Trailblazer EXT?
NHTSA has 23 complaints about the fuel & propulsion system of the 2002 Chevrolet Trailblazer EXT, 23% of the model year's 100 complaints. The component named most often is storage › tank assembly › filler pipe and cap (8 mentions).
Is there a recall for 2002 Chevrolet Trailblazer EXT fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2002 Chevrolet Trailblazer EXT, though it has 3 recalls 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 Trailblazer EXT fuel system problems start?
Half of the complaints with a recorded mileage happened before about 75,000 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.