2002 GMC Savana 3500

The 2002 GMC Savana 3500 is a full-size van known for its utility and spaciousness. It was commonly used for commercial purposes, passenger transport, and recreational vehicle conversions. While appreciated for its robust build and cargo capacity, the 2002 Savana 3500 has a number of issues reported by owners. Engine options included a 4.3L V6, 5.0L V8, 5.7L V8 and the 6.5L Turbo Diesel V8. The Vortec 5700 5.7L V8 produced around 255 horsepower and 330 lb-ft of torque. The transmission options included the 4L60E four-speed automatic transmission and the 4L80E. The older design and lack of modern amenities are often cited as downsides.

Engine

4.3L V6

• Intake Manifold Gasket Failure
  • Description/Symptoms: Coolant leak, rough running engine, overheating.
  • Solution: Replace the intake manifold gasket.
  • Estimated Cost to Fix: $300 - $500+
  • Recalls: None Found

5.0L V8 No Issues Found

5.7L V8

• Fuel Injector Failure
  • Description/Symptoms: Rough idling, misfires, decreased fuel economy, and check engine light illumination.
  • Solution: Replace faulty fuel injectors.
  • Estimated Cost to Fix: $200 - $600+
  • Recalls: None Found
• Oil Pressure Sensor Failure
  • Description/Symptoms: Inaccurate or no oil pressure reading on the gauge, check engine light.
  • Solution: Replace the oil pressure sensor.
  • Estimated Cost to Fix: $100 - $200+
  • Recalls: None Found
• Distributor Failure
  • Description/Symptoms: Engine misfires, difficulty starting, stalling, rough running.
  • Solution: Replace the distributor cap, rotor, and possibly the entire distributor assembly.
  • Estimated Cost to Fix: $150 - $400+
  • Recalls: None Found

6.5L Turbo Diesel V8

• Fuel Filter Manager Failure
  • Description/Symptoms: Air in the fuel lines, hard starting, poor performance.
  • Solution: Replace the fuel filter manager.
  • Estimated Cost to Fix: $200-$400+
  • Recalls: None Found
• Crankshaft Position Sensor Failure
  • Description/Symptoms: Engine stalling, hard starting, poor performance, no start condition.
  • Solution: Replace the crankshaft position sensor.
  • Estimated Cost to Fix: $150 - $300+
  • Recalls: None Found
• PMD (Pump Mounted Driver) Failure
  • Description/Symptoms: Stalling, erratic engine behavior, no start condition (especially when hot).
  • Solution: Relocate the PMD to a cooler location and/or replace it.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found

Transmission

4L60E

• Slipping or Harsh Shifting
  • Description/Symptoms: Transmission slips between gears, harsh or delayed shifting, or failure to shift.
  • Solution: Rebuild or replace the transmission. Could also be caused by a faulty shift solenoid, valve body issue, or worn clutches.
  • Estimated Cost to Fix: $150 - $200+
  • Recalls: None Found

4L80E

• Slipping or Harsh Shifting
  • Description/Symptoms: Transmission slips between gears, harsh or delayed shifting, or failure to shift.
  • Solution: Rebuild or replace the transmission. Could also be caused by a faulty shift solenoid, valve body issue, or worn clutches.
  • Estimated Cost to Fix: $150 - $200+
  • Recalls: None Found
• Loss of Reverse
  • Description/Symptoms: Transmission fails to engage reverse.
  • Solution: Rebuild the transmission, replacing the reverse clutches/band.
  • Estimated Cost to Fix: $150 - $200+
  • Recalls: None Found

Suspension

• Worn Ball Joints and Tie Rod Ends
  • Description/Symptoms: Clunking noises from the front end, loose steering, uneven tire wear.
  • Solution: Replace worn ball joints and tie rod ends.
  • Estimated Cost to Fix: $200 - $500+ per side.
  • Recalls: None Found
• Leaf Spring Sagging/Failure
  • Description/Symptoms: Rear end sagging, poor ride quality, reduced load capacity.
  • Solution: Replace the leaf springs.
  • Estimated Cost to Fix: $300 - $800+ per side.
  • Recalls: None Found

Electrical

• Instrument Cluster Issues
  • Description/Symptoms: Gauges failing to work properly, intermittent or complete failure of the instrument cluster.
  • Solution: Repair or replace the instrument cluster.
  • Estimated Cost to Fix: $200 - $600+
  • Recalls: None Found

Exterior

• Door Hinge Wear/Failure
  • Description/Symptoms: Difficulty opening/closing doors, sagging doors.
  • Solution: Replace door hinges.
  • Estimated Cost to Fix: $100 - $300+ per door.
  • Recalls: None Found
• Rust
  • Description/Symptoms: Rust forming around wheel wells, rocker panels, and other body panels.
  • Solution: Cut out and weld in new metal.
  • Estimated Cost to Fix: $100 - $500+ per panel
  • Recalls: None Found

Interior

• Cracked Dash
  • Description/Symptoms: Cracks appearing on the dashboard.
  • Solution: Replace dashboard, or dash cover
  • Estimated Cost to Fix: $200 - $800+
  • Recalls: None Found
• Headliner Sagging
  • Description/Symptoms: The headliner fabric detaches from the backing and begins to sag.
  • Solution: Replace the headliner.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found
• Window Regulator Failure
  • Description/Symptoms: Windows fail to go up or down.
  • Solution: Replace window regulator
  • Estimated Cost to Fix: $150 - $400+ per door
  • Recalls: None Found

Summary

The 2002 GMC Savana 3500 is a workhorse van with known issues stemming from its age. Engine issues, particularly with the 5.7L V8 and 6.5L Turbo Diesel, can be costly to repair. Transmission problems, especially slipping or harsh shifting, are also common. Suspension wear and electrical issues further contribute to potential maintenance costs. Rust is a significant concern for vehicles of this age, especially in regions with harsh winters. While some repairs are relatively inexpensive, major issues like transmission rebuilds or engine component failures can lead to significant repair bills. Overall, potential buyers should carefully inspect the vehicle for these common issues and factor in the cost of potential repairs.