The 2002 Venture with the 3.4L V6 is a workhorse minivan plagued by intake manifold gasket failures and 4T65-E transmission issues—expect both if you're buying high-mileage. The platform is mechanically simple but these two problems define ownership experience.
Symptoms: White smoke from exhaust on cold start, Coolant loss with no visible external leaks, Milky oil on dipstick or in valve covers, Rough idle and potential misfire codes
Fix: Remove upper plenum, replace lower intake gaskets (Felpro updated design mandatory), flush contaminated oil. Expect 6-8 hours labor. Often find corroded coolant elbows that need replacement simultaneously.
Estimated cost: $800-1,400
4T65-E Transmission Failure (Pressure Control Solenoid and Torque Converter)
Common · high severity
Typical onset: 80,000-140,000 mi
Symptoms: Harsh 1-2 shift or slipping between gears, Shudder during light acceleration 30-45 mph, Check Engine Light with P0741 or P1811 codes, Delayed engagement into Drive or Reverse
Fix: Pressure control solenoid replacement buys time (3 hours) but torque converter shudder usually means full rebuild or replacement. Used units are gambles; expect remanufactured trans swap at 12-15 hours.
Symptoms: Transmission fluid dripping near radiator or under engine bay, Low fluid level causing delayed shifts, Rust perforation visible on steel cooler lines
Fix: Steel lines rust through where they route near subframe. Replace both pressure and return lines as a set (avoid rubber hose patches). 2-3 hours labor, includes fluid refill.
Estimated cost: $300-550
Power Sliding Door Latch and Cable Failures
Occasional · medium severity
Symptoms: Door won't latch closed electrically but works manually, Grinding noise during power door operation, Door reverses or stops mid-cycle, Latch warning light on dash
Fix: Cable stretches or latch motor wears out. Door panel removal required, latch assembly replacement 2-3 hours per side. This was recall-worthy on some VINs but many fall outside coverage.
Estimated cost: $400-700 per door
Timing Chain Guide Wear (Secondary Timing Chain)
Occasional · high severity
Typical onset: 120,000-180,000 mi
Symptoms: Rattling noise from front of engine on cold start that fades after 5-10 seconds, Check Engine Light with cam/crank correlation codes, Plastic debris in oil during changes
Fix: Plastic guides disintegrate on secondary chain. Requires front cover removal, replace all guides, tensioner, and both chains. 10-12 hours labor; harmonic balancer often needs replacement simultaneously if original.
Estimated cost: $1,800-2,800
Fuel Tank Strap and Filler Neck Rust-Through
Occasional · medium severity
Symptoms: Fuel smell near rear of vehicle, Visible rust or fuel staining on tank straps, Difficulty filling tank (premature shutoff at pump)
Fix: Salt-belt vehicles see tank strap corrosion; filler neck rusts where it meets tank. Tank drop required, replace straps and inspect neck/hoses. 3-4 hours labor.
Estimated cost: $400-700
ABS Wheel Speed Sensor Corrosion (Front)
Occasional · low severity
Typical onset: 80,000+ mi
Symptoms: ABS light illuminated, Traction control disabled message, Codes for front wheel speed sensor circuit
Fix: Sensors corrode where they mount in knuckle. Usually right front fails first. Sensor replacement is simple (0.5 hours) but may require knuckle cleanup if corrosion severe.
Estimated cost: $150-250 per sensor
Owner tips
Flush Dexcool coolant every 30k and switch to updated intake gaskets at first sign of seepage—don't wait for catastrophic failure
Change transmission fluid every 50k with AC Delco Dexron VI and new filter; aftermarket fluids accelerate 4T65-E issues
Inspect transmission cooler lines annually in rust-belt climates; catch them early before losing fluid pressure
If buying used over 100k, budget $2k-3k for intake gaskets and transmission work—assume both are due
Solid bones but the intake gasket and transmission are ticking time bombs—only buy if already fixed with documentation or priced for inevitable $3k-4k in repairs.
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.
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DORMAN IS RECALLING 979 STEERING KNUCKLES, DORMAN P/NOS. 697-902 AND 697-903, SOLD UNDER DORMAN'S "OE SOLUTIONS<SUP>TM</SUP>" BRAND NAME, AND NAPA P/NOS. 7-8502 AND 7-8503 WHICH WERE SOLD FOR REPLACEMENT USE ON THE VARIOUS VEHICLES LISTED ABOVE. A POTENTIAL MATERIAL OR DESIGN DEFECT COULD RESULT IN THE STEERING KNUCKLE BREAKING IN THE HUB AREA.
Consequence: A BROKEN STEERING KNUCKLE COULD RESULT IN LOSS OF STEERING CONTROL AND A POSSIBLE CRASH WITHOUT WARNING.
Remedy: DORMAN WILL NOTIFY OWNERS AND REPLACE THE DEFECTIVE STEERING KNUCKLES FREE OF CHARGE AND REIMBURSE THE REPAIR FACILITY OR OWNER FOR LABOR. THE RECALL BEGAN ON FEBRUARY 23, 2009. OWNERS MAY CONTACT DORMAN'S TOLL-FREE HOTLINE AT 1-800-523-2492 AND PRESS 5.
EXTERIOR LIGHTING:HEADLIGHTS · 08E050000
2008-08-11
K2 MOTOR IS RECALLING 1,921 AFTERMARKET HEADLAMPS OF VARIOUS MODELS SOLD FOR USE ON THE ABOVE LISTED VEHICLES. THESE HEADLAMPS ARE MISSING THE AMBER SIDE REFLEX REFLECTOR WHICH FAILS TO CONFORM WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT."
Consequence: WITHOUT THE AMBER SIDE REFLEX REFLECTORS, THE LIGHTING VISIBILITY MAY BE AFFECTED, POSSIBLY RESULTING IN A VEHICLE CRASH.
Remedy: K2 MOTOR WILL NOTIFY OWNERS AND OFFER A FULL REFUND. THE RECALL BEGAN ON DECEMEBER 17, 2008. OWNERS MAY CONTACT K2 MOTOR AT 1-909-839-2992.
FUEL SYSTEM, GASOLINE:STORAGE · 07V349000
2007-08-08 · EA07006
ON CERTAIN VEHICLES, VARIATIONS IN THE MANUFACTURING PROCESS OR EXPOSURE TO HIGH AMBIENT TEMPERATURES MAY LEAD TO FRACTURE OF THE FUEL TANK INLET CHECK VALVE (ICV).
Consequence: A FRACTURE MAY ALLOW FUEL VAPORS TO PASS THROUGH AND ALLOW DROPLETS OF FUEL TO ACCUMULATE ON THE SIDE OF THE FUEL TANK. FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
Remedy: DEALERS WILL REPLACE THE FUEL TANK. THE RECALL WILL BE MAILED IN TWO PHASES WITH THE FIRST PHASE BEGINNING ON DECEMBER 4, 2007. THE SECOND PHASE WILL BE MAILED ON DECEMBER 13, 2007. OWNERS MAY CONTACT BUICK AT 1-866-608-8080; CHEVROLET AT 1-800-630-2438; OR PONTIAC AT 1-800-620-7668. THE VEHICLE POPULATION INCLUDES BUICK RENDEZVOUS AND PONTIAC AZTEK VEHICLE BUILT IN MAY 2003; CHEVROLET VENTURE AND PONTIAC MONTANA VEHICLES BUILT FROM JUNE THROUGH AUGUST 2002; AND ALL VEHICLES REGISTERED IN NEVADA, ARIZONA, VIRGIN ISLANDS, PUERTO RICO, AND HAWAII.
CERTAIN DELPHI FUEL PRESSURE REGULATORS, P/NOS. FP10020-11B1, FP10026-11B1, AND FP10027-11B1, SOLD AFTER JANUARY 9, 2007, AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES LISTED ABOVE. THE UNIVERSAL PRESSURE REGULATORS (UPR) WERE PRODUCED WITHOUT AN O'RING AND RETAINER.
Consequence: FUEL MAY LEAK, POSSIBLY RESULTING IN A FIRE.
Remedy: DELPHI WILL NOTIFY OWNERS AND REPLACE THE UPR FREE OF CHARGE. THE RECALL BEGAN ON APRIL 23, 2007. OWNERS CAN CONTACT DELPHI AT 877-411-8770.
LATCHES/LOCKS/LINKAGES:DOORS:LATCH · 04V597000
2004-12-22 · PE04064
ON CERTAIN MINIVANS EQUIPPED WITH SECOND-ROW BUCKET SEATS OR CAPTAIN'S CHAIRS AND A POWER SLIDING DOOR ON THE PASSENGER SIDE OF THE VEHICLE, A PASSENGER USING THE INTERIOR HANDLE TO OPEN THE POWER SLIDING DOOR COULD BE INJURED.
Consequence: IF A PASSENGER USES THE INTERIOR HANDLE TO OPEN THE POWER SLIDING DOOR AND HOLDS ONTO THE HANDLE WHILE IT IS BEING OPENED BY THE MOTOR, THE PASSENGER'S ARM MAY BE PUSHED INTO THE SEAT BACK OR ARMREST AND A WRIST OR LOWER ARM INJURY MAY RESULT.
Remedy: DEALERS WILL REPLACE THE POWER SLIDING DOOR INTERIOR HANDLE ON THE PASSENGER-SIDE. IF THE VEHICLE IS EQUIPPED WITH A POWER OR MANUAL SLIDING DOOR ON THE DRIVER-SIDE, THE INTERIOR HANDLE WILL ALSO BE REPLACED FOR APPEARANCE REASONS. NOTE: BEFORE THE VEHICLE IS SERVICED, GM ADVISES OWNERS TO NOT USE THE INTERIOR DOOR HANDLE TO OPEN THE DOOR. THE DRIVER CAN OPEN AND CLOSE THE DOOR FROM SWITCHES AT THE DRIVER'S POSITION OR BY USING THE REMOTE KEY FOB. THE DRIVER SHOULD TELL PASSENGERS TO USE THE SWITCH LOCATED IN FRONT OF THE DOOR TO OPEN OR CLOSE IT. THE DRIVER SHOULD USE THE OVERRIDE SWITCH TO PREVENT OPERATION OF THE POWER DOOR BY CHILDREN OR BY OTHERS WHO ARE NOT FAMILIAR WITH ITS USE.
THE OWNER NOTIFICATION LETTER MAILING WILL BE CONDUCTED IN PHASES WITH THE FIRST PHASE BEGINNING ON MAY 31, 2005. THE SECOND PHASE MAILING BEGAN ON JULY 18, 2005. THE RECALL BEGAN ON MAY 31, 2005. PHASE 2 BEGAN ON JULY 18, 2005. PHASE 3 (FINAL PHASE) BEGAN ON AUGUST 24, 2005, TO ALL REMAINING CUSTOMERS. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438; PONTIAC AT 1-800-620-7668; OR OLDSMOBILE AT 1-800-630-6537.
AIR BAGS:FRONTAL · 02V222000
2002-08-09
CERTAIN PASSENGER, MINI VANS, AND SPORT UTILITY VEHICLES HAVE AN AIR BAG INFLATOR ON THE DRIVER'S SIDE THAT COULD FRACTURE AT A WELD DURING A DEPLOYMENT.
Consequence: PIECES OF THE INFLATOR COULD STRIKE AND INJURE VEHICLE OCCUPANTS AND THE AIR BAG CUSHION WOULD NOT INFLATE FULLY, REDUCING THE CAPABILITY OF THE BAG TO PROTECT THE DRIVER.
Remedy: DEALERS WILL INSPECT, AND REPLACE, IF NECESSARY, THE AIR BAG MODULE ASSEMBLY ON THE DRIVER'S SIDE. OWNER NOTIFICATION BEGAN AUGUST 15, 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 BUICK AT 1-800-521-7300, CADILLAC AT 1-800-458-8006, CHEVROLET AT 1-800-222-1020, GMC AT 1-800-462-8782, OLDSMOBILE AT 1-800-442-6537, OR PONTIAC AT 1-800-762-2737.
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