2002 GMC Envoy

2002 GMC Envoy

Overview

The 2002 GMC Envoy, a mid-size SUV, offered a blend of comfort and utility, often serving as a family vehicle. It was built on the GMT360 platform, sharing its underpinnings with other GM SUVs of the era. While generally considered a capable vehicle for its time, like many vehicles from this period, it has specific areas that have shown more frequent issues as it ages. Owners often reported on the reliability of its powertrain and the general wear and tear associated with a vehicle of this age. Understanding these common points of failure can help current and prospective owners manage maintenance and repair costs effectively.

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Engine

4.2L Atlas I6

Intake Manifold Gasket Leaks

• Symptoms: Coolant leaks, sweet smell of coolant, engine misfires, overheating.
• Solution: Replacement of the intake manifold gasket.
• Cost: $300 - $600

Oil Cooler Lines Leaking

• Symptoms: Oil in coolant reservoir, coolant leaks, low oil pressure.
• Solution: Replacement of leaking oil cooler lines.
• Cost: $400 - $700

5.3L Vortec V8

Active Fuel Management (AFM) lifter failure

• Symptoms: Engine knocking or ticking noise, rough idle, check engine light, loss of power.
• Solution: Replacement of lifters, camshaft, and potentially oil pump. AFM system may need to be disabled.
• Cost: $1500 - $3000+

Intake Manifold Gasket Leaks

• Symptoms: Coolant leaks, sweet smell of coolant, engine misfires, overheating.
• Solution: Replacement of the intake manifold gasket.
• Cost: $300 - $600

Transmission

4L60-E (4-Speed Automatic)

Torque Converter Issues

• Symptoms: Slipping, shuddering, delayed engagement, overheating.
• Solution: Rebuild or replacement of the torque converter and potentially transmission.
• Cost: $800 - $2000+

Solenoid Failure

• Symptoms: Harsh shifting, failure to shift into certain gears, transmission warning light.
• Solution: Replacement of faulty shift solenoids.
• Cost: $400 - $800

Suspension

Standard Chassis

Front Wheel Bearing Failure

• Symptoms: Grinding or humming noise from front wheels, especially when turning.
• Solution: Replacement of the front wheel bearing assembly.
• Cost: $300 - $600

Ball Joint Wear

• Symptoms: Clunking noises over bumps, uneven tire wear, steering looseness.
• Solution: Replacement of worn ball joints.
• Cost: $400 - $700

Electrical

Body Control Module (BCM)

Intermittent Electrical Gremlins

• Symptoms: Power windows not working, interior lights flickering, door locks malfunctioning, dashboard warning lights.
• Solution: Diagnosis and potential reprogramming or replacement of the BCM.
• Cost: $500 - $1000+

Alternator

Alternator Failure

• Symptoms: Dimming headlights, battery warning light, dead battery, electrical system malfunctions.
• Solution: Replacement of the alternator.
• Cost: $400 - $700

Exterior

Body Panels & Trim

Rust on Body Panels

• Symptoms: Visible rust, bubbling paint, especially on lower body panels, wheel wells, and rocker panels.
• Solution: Rust repair and repainting, or replacement of affected panels.
• Cost: $200 - $1500+ (depending on severity)

Headlight Lenses

Clouding/Yellowing of Headlight Lenses

• Symptoms: Reduced light output, poor visibility at night, aesthetic degradation.
• Solution: Restoration kit or replacement of headlight assemblies.
• Cost: $50 - $300

Interior

HVAC System

Blend Door Actuator Failure

• Symptoms: Inability to control temperature (stuck on hot or cold), air only coming from certain vents.
• Solution: Replacement of the blend door actuator(s).
• Cost: $200 - $500

Dashboard/Trim

Cracked Dashboard

• Symptoms: Visible cracks in the dashboard material, especially on the top surface.
• Solution: Dashboard cover or replacement.
• Cost: $100 - $800+

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Summary Verdict

The 2002 GMC Envoy, particularly with the 4.2L Atlas I6 engine, is generally considered to have a more robust powertrain than the V8 option, which can be prone to AFM-related issues. Transmission reliability is decent, but torque converter and solenoid issues are not uncommon as the vehicle ages. Suspension components like wheel bearings and ball joints are typical wear items that require attention. Electrical gremlins, often stemming from the BCM, and alternator failures are also reported. Exterior rust can be a significant concern depending on climate. Interior issues like blend door actuators and dashboard cracking are also noted. Overall, while capable, expect to address age-related issues, especially in the powertrain and electrical systems.