The 2002 GMT800 Yukon is a workhorse platform with rock-solid front suspension and frame, but it's plagued by transmission failures, intake manifold gasket leaks, and fuel system issues that can strand you. The 4.8L and 5.3L engines are generally reliable if the intake gaskets are addressed early; the 6.0L sees more bottom-end failures.
4L60E/4L65E Transmission Failure
Common · high severity
Typical onset: 120,000-180,000 mi
Symptoms: harsh 1-2 shift or slipping in 2nd gear, delayed engagement into drive or reverse, transmission overheating, burnt fluid smell, check engine light with P0741 or P1870 codes
Fix: Rebuild or replace transmission. 3rd and 4th clutch packs burn up, torque converter fails. Rebuilt units last if the cooler lines are flushed and external cooler added. 8-12 labor hours for R&R plus rebuild time.
Estimated cost: $2,200-3,800
Intake Manifold Gasket Leak (Vortec V8s)
Common · medium severity
Typical onset: 80,000-150,000 mi
Symptoms: coolant loss with no visible external leak, white smoke on cold start, rough idle or misfire codes, coolant in oil (milky dipstick) in severe cases
Fix: Replace plastic intake manifold gaskets with updated Fel-Pro composite set. Also inspect distributor O-ring. 4-6 labor hours. Critical to address before it causes bearing damage from coolant dilution.
Estimated cost: $600-1,200
Fuel Pump and Fuel Pressure Regulator Failure
Common · high severity
Typical onset: 100,000-160,000 mi
Symptoms: hard starting, especially when hot, loss of power under load or uphill, stalling at idle after driving, strong fuel smell from tailpipe (regulator diaphragm leak)
Fix: Drop fuel tank to replace pump assembly and/or pressure regulator. Tank straps rust on northern vehicles, add time. Pump failure leaves you stranded. 3-5 labor hours depending on rust and 4WD skid plates.
Estimated cost: $650-1,100
ABS Module/Pump Failure and Brake Line Corrosion
Occasional · high severity
Typical onset: 120,000+ mi
Symptoms: ABS light on with C0265 or C0241 codes, grinding/clicking from ABS pump on startup, spongy brake pedal, brake fluid leaks at rear brake hoses or steel lines at frame
Fix: ABS module rebuild or replacement ($400-800 part). Brake lines rot at frame brackets in rust belt. Full brake line replacement job is 6-8 hours. Module R&R is 2-3 hours, requires scan tool bleeding.
Estimated cost: $800-2,000
Instrument Cluster Stepper Motor Failure
Common · low severity
Typical onset: 100,000-180,000 mi
Symptoms: speedometer, fuel gauge, or other gauges intermittent or dead, needles bouncing or stuck, no effect on driveability but annoying and fails inspection in some states
Fix: Remove cluster and replace individual stepper motors (solder job) or send to rebuild service. DIY-friendly if you can solder. 1-2 hours removal/reinstall, plus motor replacement time.
Estimated cost: $150-450
EVAP Vent Solenoid and Purge Valve Issues
Occasional · low severity
Typical onset: 90,000-140,000 mi
Symptoms: check engine light P0440, P0446, P0455 EVAP codes, fuel smell near rear wheel well, difficulty filling gas tank (clicks off repeatedly)
Fix: Replace vent solenoid on top of fuel tank or purge valve near intake. Vent solenoid requires tank drop. 0.5 hour for purge valve, 3-4 hours for vent solenoid due to tank access.
Estimated cost: $200-700
Front Differential Fluid Leak and Axle Actuator Failure (4WD)
Occasional · medium severity
Typical onset: 100,000+ mi
Symptoms: gear oil drips on garage floor from front diff, 4WD won't engage or service 4WD message, grinding or clunking when engaging 4WD, front axle actuator clicking but not engaging
Fix: Replace front diff seals or axle actuator. Actuator is thermal plastic, cracks over time. 2-3 hours for actuator, 3-4 hours for diff seal with axle shaft removal.
Estimated cost: $400-900
Exhaust Manifold Bolts Breaking and Manifold Cracks
Occasional · low severity
Typical onset: 120,000+ mi
Symptoms: ticking/tapping noise on cold start, loudest first 30 seconds, exhaust leak smell in cabin with heater on, visible soot streaks on manifold
Fix: Extract broken bolts, install manifold with new gaskets and bolts. Passenger side is easy, driver side requires removal of steering shaft. 3-6 hours depending on side and bolt extraction difficulty.
Estimated cost: $500-1,200
Owner tips
Change transmission fluid every 50k miles and add an auxiliary cooler to extend 4L60E life—these transmissions run hot towing or in stop-and-go traffic
Address intake manifold gasket leaks immediately; coolant in the oil will destroy bearings in under 5,000 miles
Use Dexcool-compatible coolant only and flush every 3 years; mixing with green coolant causes sludge that clogs heater cores
Inspect brake lines annually in rust-belt states; these rot from the inside out at the frame clips
Keep fuel tank above 1/4 full to prolong fuel pump life—these pumps use fuel for cooling
Buy one if the transmission has been rebuilt and the intake gaskets replaced; pass if it has 150k+ on the original trans or shows coolant loss—otherwise a solid truck that's cheap to own.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
Fitment notes: Side post terminals standard on GM vehicles; battery located under hood on passenger side
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Every control module on the 2000-2006 GMC Yukon — where it lives, replacement time, and what it takes to program a replacement. Modules marked dealer / factory tool won't work after a part swap alone — budget for programming.
⚠️ Stores seat and mirror positions. May require position relearn after replacement.
Trailer Brake Control Module (TBCM)0.8 hr R&Rrelearn only +0.2 hrwith factory trailer brake controller▸ programming details
📍 Under instrument panel, left of steering column near fuse panel
🔧 Tech 2
⚠️ Integrated trailer brake controller. Calibration and gain settings required.
Aftermarket tool coverage varies by software version and vehicle build — treat "aftermarket tool" rows as "usually possible" and verify against your tool maker's coverage list before promising a customer. Spot a wrong location or hour? Tell us — corrections ship fast here.
CERTAIN FEDERAL-MOGUL REPLACEMENT WHEEL HUB ASSEMBLIES WITH THE BRAND NAMES: NATIONAL, CARQUEST P/NOS. 515020, 515021, 515025, 515053, 515054, 515059, AND 515060, SHIPPED BETWEEN JANUARY 23, 2006, AND DECEMBER 20, 2007, SOLD FOR LIGHT DUTY AND MEDIUM DUTY TRUCKS. THE INBOARD RETENTION NUT USED TO MAINTAIN HUB BEARING ASSEMBLY CAN LOOSEN RESULTING IN AN ABS LIGHT INDICATION, NOISE, AND/OR WHEEL SEPARATION.
Consequence: WHEEL SEPARATION CAN RESULT IN A VEHICLE CRASH.
Remedy: FEDERAL-MOGUL WILL NOTIFY CUSTOMERS AND WILL REPLACE THE HUB ASSEMBLY FREE OF CHARGE. THE RECALL BEGAN ON FEBRUARY 7, 2008. OWNERS CAN CONTACT FEDERAL-MOGUL TOLL-FREE AT 877-489-6659.
FUEL SYSTEM, GASOLINE · 06E043000
2006-05-19
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).
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP · 05V379000
2005-08-29 · PE05020
CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES MAY EXPERIENCE UNWANTED ANTILOCK BRAKE SYSTEM (ABS) ACTIVATION. THIS CONDITION IS MORE LIKELY TO OCCUR IN ENVIRONMENTALLY CORROSIVE AREAS. THIS RECALL WILL BE LAUNCHED IN THE "SALT BELT" STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MARYLAND, MASSACHUSETTS, MAINE, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN AND THE DISTRICT OF COLUMBIA ONLY.
Consequence: THIS CAN CAUSE INCREASED STOPPING DISTANCES DURING LOW-SPEED BRAKE APPLICATIONS, WHICH COULD RESULT IN A CRASH.
Remedy: DEALERS ARE TO REMOVE THE WHEEL SPEED SENSOR AND THOROUGHLY CLEAN THE WHEEL SPEED SENSOR MOUNTING SURFACE ON THE BEARING, APPLY RUST INHIBITOR TO THE CLEANED SURFACE, GREASE THE MOUNTING SURFACE, REINSTALL THE WHEEL SPEED SENSOR, AND CHECK THE PEAK-TO-PEAK OUTPUT VOLTAGE TO ENSURE THE WHEEL SPEED SIGNAL IS WITHIN SPECIFICATIONS. THE RECALL BEGAN SEPTEMBER 22, 2005. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438 OR GMC AT 1-866-996-9463.
STRUCTURE · 03V094000
2003-03-07
CERTAIN PICKUP TRUCK, VAN, AND MINI VAN CONVERSIONS EQUIPPED WITH SOUTHERN COMFORT BUILT RUNNING BOARDS THAT CONTAIN CERTAIN COURTESY LIGHTS MANUFACTURED BY AMERICAN TECHNOLOGY COMPONENTS, INC. THESE UNITS CONTAIN A COURTESY LIGHT OR LIGHTS THAT MIGHT OVERHEAT WHEN THE WIRE HARNESS IS EXPOSED TO EXCESSIVE MOISTURE AND ROAD SALT.
Consequence: THIS OVERHEATING CONDITION CAN CAUSE THE RUNNING BOARD TO MELT OR CAUSE A FIRE.
Remedy: DEALERS WILL REPLACE THE WIRING HARNESS ON THESE RUNNING BOARDS. OWNER NOTIFICATION BEGAN MARCH 7, 2003. 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 SOUTHERN COMFORT AT 1-800-745-6096.
SEATS:FRONT ASSEMBLY:HEAD RESTRAINT · 02V253000
2002-09-17
ON CERTAIN SPORT UTILITY VEHICLES EQUIPPED WITH REARWARD FOLDING HEAD RESTRAINTS ON THE SECOND ROW SEATS, TWO POTENTIAL PINCH POINTS EXIST ON EACH OF THE FOLDING HEAD RESTRAINTS WHEN THE RESTRAINTS ARE FOLDED REARWARD AS THE SEATBACK IS FOLDED DOWN.
Consequence: IF A PERSON WERE TO INSERT THEIR FINGER(S) INTO THE PINCH POINT WHEN THE HEAD RESTRAINT FOLDS, IT COULD TRAP AND PINCH THE FINGER(S) CAUSING INJURY.
Remedy: DEALERS WILL INSTALL PROTECTIVE COVERS OVER THE PINCH POINTS. OWNER NOTIFICATION BEGAN NOVEMBER 8, 2002. 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, GMC AT 1-800-462-8782, OR CADILLAC AT 1-800-458-8006.
Performance
Horsepower
275hp
Torque
290lb-ft
0–60 mph
10.2sec
Quarter mile
17.8sec
Top speed
105mph
Fuel economy (EPA)
City
13mpg
Highway
18mpg
Combined
15mpg
Fuel
Regular Gasoline
Capability & size
Towing capacity
6,200lb
Payload
1,450lb
Curb weight
5,315lb
EPA class
Sport Utility Vehicle - 2WD
Wiper blades
GMT800 platform (2000-2006 generation). Standard hook attachment.
Size-standard part numbers — verify your connector type before buying. Rear blades are model-specific; check the package's vehicle list.
Fuel economy figures are EPA data via fueleconomy.gov (median across matching trims). Performance figures are compiled estimates for the 2002 GMC Yukon 4.8L V8 Vortec and can vary by trim.
🔧 Database maintained under the daily editorial review of Chris Hackleman · Master Technician · 20+ years and Jeff Moore · Master Lexus & Toyota Mechanic · 20+ years.