Which parts fail
Components named in complaints (service brakes, ABS, rotors and pads, parking brake).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2002 GMC Sierra 2500 owners, lightly cleaned up (personal details are redacted by NHTSA).
I was driving my 2002 GMC Sierra 2500 hd on i95 when traffic came to a sudden stop. I slammed on the brakes at which point the ABS system started pulsing the brakes, but the brake pedal suddenly went to the floor with no further brake response. Thankfully, the brakes slowed the truck enough prior to failure to prevent a collision at 65 MPH. I hit the car in front of me at ~5-10 MPH, causing bumper damage to my truck and the car in front of me. I was able to get the car to the side of the road and to my horror I had no brakes. The vehicle was towed to a local authorized GMC dealer who has maintained the truck for me. They confirmed that the brake lines catastrophically failed when I slammed on the brakes. The rusted brake lines burst when I slammed on the brakes. They indicated that all of the brake lines had to be replaced do to rust throughout. …
I have owned many GM trucks, and never had one with so many rusted out brake lines. Why can't they make them with stainless steel lines. They should have a recall for this. What happens when front and back lines go at the same time, I will tell you, no brakes ! This is the worst one with the rust that I have had. 3 lines rust out on the GMC 2500 hd (2002) with more to come, I have 25,000 miles on this truck. The first line went about 15,000 miles. Also I only got about 5,000 miles on those Firestone tires, cheap tires come with this truck. I have also noticed the frame is rusting, had to have the cable replaced that shifts the truck into gear, it rusted out. I go to the car wash and always wash the underside of the truck to get all the dirt and salt off every chance I get. …
I purchase this truck 2/03/17 and have used it until 2 weeks age when the brake lines broke in my driveway, I am having the lines replaced with stainless lines at a cost of about $1200 ( I am not sure of the total cost because it also needs a antilock braking pump which was badly corroded) the fuel lings are also rusted and need to be replaced and also the transmission cooling lines need to be replaced at a cost to be determined later. I have a 1953 Chevy pickup that still has good brake lines and the frame is in better shape than the newer ones, if GM looked to the past at the materials & methods they might build a better product rather than the garbage they produce now! I am glad I didn't pay $30-$60,000 for this truck.
The vehicle was parked on a 35-40 degree sloped driveway. Got in, stepped on brake,started vehicle, released emergency brake, shift into reverse, and brake pedal went to the floor, with truck rolling backwards. Wheel was turned, and truck hit a side of retaining wall. It did not roll back excessively fast, but it could not stop in time to avoid hitting the wall. Found badly corroded brake lines. One had ruptured right behind the driver's front wheel fender well.
Driving into driveway applied brakes , pedal went right to the floor no warning light or any indication of a problem got out of truck and found fluid dripping off frame by fuel tank. Ruptured line above tank on frame, other brake lines also look corroded. After some research I found this to be a common problem on GM trucks . Owners need to be made aware of this problem before someone is seriously hurt. I believe GM should be forced to repair the defective lines.
Backing my truck down a boat launch to put a pwc in. As I applied the brake at the bottom of the ramp, the pedal went to the floor, losing all brakes. Since I was close to the water, by the time I got it into forward, it was already over the edge of the ramp into the water. Submerged up to the bottom of the roof. A total loss.
Tl* the contact owns a 2002 GMC Sierra 2500 hd. The contact stated that while driving 5 MPH, when the brake pedal was depressed and the brakes failed. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was 60,000.
Brakes went out no warning, after looking on drivers side seat under truck where fluid was running out saw where brake line was rusted and it busted. So I took several pictures and called GMC, they in turn towed my truck to auffenberg of carbondale, illinois at no charge. At this time I started researching the rusted brake problem and found where alan adler (manager product safety communications) for GM said on (abc news rusted brake lines) where they were offering a (kit) to have the rusted brake lines repaired for a cost to us of $500.00. So now today 06/05/2014 my truck is done at a cost of $1188.05 to me for the dealer knows nothing of this. I have tried to contact alan adler through GM and no one knows who he is, I have sent many complaints and talked with many people and no one seems to know what I am talking about. My ref.# [redacted] with the complaint dept. …
A break line ruptured resulting in loss of fluid and diminished breaking. Fortunately it did not result in a catastrophic loss in breaking at a critical time. The ruptured line is near the gas tank and at first appeared to be a gas leak. Upon inspection all break lines are substantially rusted and must be replaced to maintain safety. One rusty line could indicate damage or a single defective part. 100% of the lines being corroded to an unsafe level indicates substandard parts. The rear disc breaks have been a constant problem with corrosion of sliding parts resulting in calipers not moving freely. The spongy feel to the breaks was attributed to sticking of the rear calipers rather than a fluid leak. Annual lubrication and a total replacement of rear breaks has become normal practice. …
Dt*: the contact stated the vehicle stalled on three occasions. All incidents occurred during acceleration while traveling 25 to 35 MPH. There were no warnings prior to the incidents and the vehicle had no problems restarting. The dealer could not duplicate or resolve the problem. Updated 11/16/2006 - there were subsequent problem restarting the vehicle, and as many as 3 to 5 stalling episodes per week. Not all incidents occurred while traveling. Some incidents occurred while at idle, and at a stop. Complete loss of power steering and brakes occurred when the vehicle stalled. The dealer diagnosed the problem as a faulty crankshaft sensor and replaced it. Recently the check engine light has illuminated. The dealer diagnosed the problem as a faulty transmission selector position sensor and replaced it. The ABS activated while driving on dry pavement. …
NHTSA investigations
Hydraulic pump shaft failures
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…
Brake complaints in other Sierra 2500 years
Frequently asked questions
How common are brake problems on the 2002 GMC Sierra 2500?
NHTSA has 78 complaints about the brakes of the 2002 GMC Sierra 2500, 58% of the model year's 134 complaints. The component named most often is antilock/traction control/electronic limited slip (11 mentions).
Is there a recall for 2002 GMC Sierra 2500 brake problems?
No. NHTSA lists no brakes recall for the 2002 GMC Sierra 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 GMC Sierra 2500 brake problems start?
Half of the complaints with a recorded mileage happened before about 90,000 miles, and 7% before 25,000 miles.
Is it dangerous?
Owners linked 6 crashes, 0 fires and 1 injury to brakes 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.