2002 GMC Savana 2500

The 2002 GMC Savana 2500 is a full-size van known for its utility and reliability. Engine options included a 4.3L V6, a 5.0L V8, a 5.7L V8, and a 6.0L V8. The 5.7L V8 produced around 255 horsepower and 330 lb-ft of torque. Owners often appreciate the Savana’s spaciousness, payload capacity, and relatively simple mechanics. Common complaints include the van’s fuel economy, handling characteristics, and the age-related deterioration of components.

Engine

4.3L V6

• Intake Manifold Gasket Failure
  • Description/Symptoms: Coolant leaks, rough running engine, overheating, and white smoke from the exhaust.
  • Solution: Replace the intake manifold gasket.
  • Estimated Cost to Fix: $300 - $600+
  • Recalls: None Found

5.7L V8

• Oil Pressure Sensor Failure
  • Description/Symptoms: Erratically fluctuating or zero oil pressure reading on the dashboard gauge, leading to misdiagnosis and potential engine damage if ignored.
  • Solution: Replace the oil pressure sensor.
  • Estimated Cost to Fix: $100 - $200+
  • Recalls: None Found
• Fuel Injector Failure
  • Description/Symptoms: Misfires, rough idle, poor fuel economy, and difficulty starting.
  • Solution: Replace the faulty fuel injector(s).
  • Estimated Cost to Fix: $150-$300+ per injector (depending on location and labor)
  • Recalls: None Found

6.0L V8

• Knock Sensor Failure
  • Description/Symptoms: Check engine light, reduced engine power, and poor fuel economy.
  • Solution: Replace the knock sensor(s) and potentially the wiring harness.
  • Estimated Cost to Fix: $200 - $400+
  • Recalls: None Found

Transmission

4L60E (All Engines)

• Slipping or Harsh Shifting
  • Description/Symptoms: Delayed engagement, erratic shifts, or “flare” between gears. Often related to worn clutches and/or valve body issues.
  • Solution: Transmission rebuild or replacement. Could also be valve body replacement depending on severity.
  • Estimated Cost to Fix: $2,000 - $4,000+ for rebuild/replacement; $500 - $1,500+ for valve body.
  • Recalls: None Found
• Torque Converter Failure
  • Description/Symptoms: Shuddering or vibration at certain speeds, especially under light acceleration. Can also cause transmission overheating.
  • Solution: Replace the torque converter.
  • Estimated Cost to Fix: $500 - $1,200+
  • Recalls: None Found

Suspension

• Worn Ball Joints
  • Description/Symptoms: Clunking noises from the front suspension, especially when going over bumps or turning. Excessive tire wear.
  • Solution: Replace the worn ball joints.
  • Estimated Cost to Fix: $200 - $500+ per side
  • Recalls: None Found
• Worn Leaf Springs
  • Description/Symptoms: Sagging rear suspension, reduced load-carrying capacity, poor ride quality.
  • Solution: Replace the leaf springs.
  • Estimated Cost to Fix: $400 - $800+ per side
  • Recalls: None Found

Electrical

• Fuel Pump Failure
  • Description/Symptoms: Difficulty starting, stalling, or complete fuel delivery failure.
  • Solution: Replace the fuel pump.
  • Estimated Cost to Fix: $300 - $700+
  • Recalls: None Found
• Blower Motor Resistor Failure
  • Description/Symptoms: Loss of one or more blower motor speeds (e.g., only high speed works).
  • Solution: Replace the blower motor resistor.
  • Estimated Cost to Fix: $50 - $200+
  • Recalls: None Found

Exterior

• Rust on Rocker Panels and Wheel Arches
  • Description/Symptoms: Visible rust forming on the lower body panels, particularly the rocker panels and wheel arches. Common in areas with road salt.
  • Solution: Rust repair, including cutting out rusted metal and welding in new panels, followed by painting.
  • Estimated Cost to Fix: $500 - $2,000+ (depending on severity and extent of damage)
  • Recalls: None Found

Interior

• Cracked Dashboard
  • Description/Symptoms: Cracks appearing on the dashboard surface, particularly in areas exposed to direct sunlight.
  • Solution: Dashboard replacement or installation of a dashboard cover.
  • Estimated Cost to Fix: $200 - $800+ for cover; $800 - $1500+ for replacement
  • Recalls: None Found

Summary

The 2002 GMC Savana 2500, while generally a reliable workhorse, does suffer from age-related issues. The most concerning problems often involve the transmission (slipping/harsh shifting) and engine (oil leaks, sensor failures), which can lead to significant repair costs. Suspension wear (ball joints, leaf springs) is also common. Rust, especially in colder climates, is a significant concern. The cost of repairs can vary widely, from a few hundred dollars for minor electrical fixes to several thousand for transmission work.