'02 Crew - Lots of issues, back in business (long)

[db11053]

I'm not sure how long it's been since I last posted, but a lot has happened since. This past spring I was looking for someone to take over my lease, but didn't get much response so I decided to keep the truck. I figured I'd post my adventures just incase anyone else is having similar problems.

A lot of things started popping up over the next few months. My main concern was regarding a problem with the HVAC system, which had been "repaired" three times for a vacuum leak, and it came back every time. I ended up contacting GMC and requesting a "buy back" on my lease. They told me they wanted to give it another shot, so I was then put in contact with the service manager at my dealer so it could be handled directly. He took my truck right away and gave me a loaner, no problem there.

Before I got GMC involved, they had replaced the entire HVAC panel on the first visit, then only the control knob/switch (vent control) because of a hissing noise and no bi-level control, both times it came back. The third time their investigation revealed a failed x-fer case actuator, which leaked fluid into the vacuum lines, so they replaced the actuator, control switch and "cleaned the lines". Noise was gone, came back a few weeks later w/inop bi-level switch again...Finally, after I had called GMC and the manager had the truck in the shop, they got help from regional rep and were instructed to replace all related components. They replaced all vac actuators in the dash, all vac lines, some related a/c components and installed a new HVAC control switch. Quite the project just for a hissing noise...but it now works better than new.

Next came a failed driver window switch. They replaced the switch, fixed.

I also complained about the window sills on both sides, how they kept popping up like almost all do on those trucks. They glued them down, fixed.

The gaskets were all coming out of the door handles on the driver side, so they replaced the handle assemblies. Seems good now, no draft through the inside handle.

Engine made whistling noise around 2500 rpm, so they installed the new tensioner kit....AND found that the intake gasket had blown, they found coolant in the oil....Engine now has new intake gasket, timing chain kit & clean oil (I'd be more concerned about that, but it IS a lease).

I found the tsb about the parking brake cable rubbing on its support, they lubed it. We'll see how long the low speed squeak stays away.

I still could hear a sucking-type sound at idle and ringing (like bells) around 3K rpm after all of this, so I had them come and get it, they had to reposition the fuel lines away from the firewall (idle noise) and further apart from each other (ringing).

On top of all of this, my differential had locked up while going around a corner a few weeks prior. It initially locked because I hit an uneven spot while making the turn (from a stop), but wouldn't unlock until I could put it in reverse. I pulled into my customer's parking lot and left a nice black mark with the outside tire, and let him know I had arrived, pretty embarrassing. The service manager stated it may be because the dif. fluid was orig. (now at 25K miles)...couldn't argue, had them change the fluid at my expense.

I also told them about a delay in the transmission when going from rev to drive (seems rather common). They of course couldn’t duplicate, so I continue to live with that minor annoyance.

All said and done, I only had to pay for the diff. fluid change, everything else was warranty, as expected.

After all of this, I can say I’m pretty surprised how well the truck came out. Everything seems good, hopefully it’ll stay that way. I've been visiting the forum regurlarly, keeping up on any new tsb postings and such, but I kind of lost the will to post during the darkest hours. I hope to do more posting here on the site, however the truck will actually be driven by my wife once her lease is up on the Tracker in Jan. I’ll be driving our ’00 Astro AWD, but we will share the truck….right. I can say that I’ve gained some respect for the truck now that I’ve read so much about and seen the new Colorado. My engine has more grunt, my interior is no worse (not as flimsy, either) and I’ve got rear discs. The frame may be a little flexible, but it's plenty strong. If the new trucks had coil-overs in the front, rear disc brakes & more engine, I’d feel differently, but I don’t see that happening anytime soon. Seems like a lot of people share at least some of that opinion.

I do apologize for such a long post, can’t blame anyone for skimming, but maybe someone can benefit from my experiences.

Derek in Mid-Michigan
'02 ZR5

[quickbiker]

[ludwis]

I hear what your sayin db11053, I just had my heater control switch replaced. http://www.s-10crewcab.com/phpbb2/viewtopic.php?t=1329
It sounds like they replaced alot of the same parts, hopefully it won't progress any further.

[HenryJ]

Here's a similar thread on ZR2.com- HVAC , transfer case, leaking & bad technician issues

It includes a link to: Secret warranties