2002 GMC Yukon XL 2500

The 2002 GMC Yukon XL 2500 is a heavy-duty, full-size SUV known for its towing capacity and spacious interior. Engine options for this model year include the 6.0L Vortec V8 (300 hp, 360 lb-ft of torque) and the 8.1L Vortec V8 (340 hp, 455 lb-ft of torque). The 4L80E four-speed automatic transmission was standard across all engine configurations. Owners generally appreciate the Yukon XL 2500 for its robustness and ability to handle demanding tasks, while common complaints revolve around fuel economy and age-related component failures.

Engine

6.0L Vortec V8

• Intake Manifold Gasket Leak
  • Description/Symptoms: Engine may run rough, exhibit a vacuum leak, and trigger a check engine light. Coolant may leak externally.
  • Solution: Replace the intake manifold gaskets.
  • Estimated Cost to Fix: $300 - $600
  • Recalls: None Found
• Oil Pressure Sensor Failure
  • Description/Symptoms: Erratic or inaccurate oil pressure gauge readings. Check engine light may illuminate.
  • Solution: Replace the oil pressure sensor.
  • Estimated Cost to Fix: $100 - $200
  • Recalls: None Found

8.1L Vortec V8

• Exhaust Manifold Bolts Breaking
  • Description/Symptoms: Exhaust leak, ticking noise, reduced engine performance.
  • Solution: Replace broken exhaust manifold bolts and potentially the manifold itself if warped.
  • Estimated Cost to Fix: $400 - $800+
  • Recalls: None Found

Transmission

4L80E Four-Speed Automatic

• Harsh Shifting
  • Description/Symptoms: Hard or delayed shifts between gears. Could be more noticeable between 1st and 2nd gear.
  • Solution: Perform a transmission fluid flush. May require replacing the transmission filter and/or shift solenoids.
  • Estimated Cost to Fix: $150 - $500+
  • Recalls: None Found
• Torque Converter Failure
  • Description/Symptoms: Shuddering at highway speeds, stalling when coming to a stop, or complete loss of power.
  • Solution: Replace the torque converter and flush the transmission fluid.
  • Estimated Cost to Fix: $800 - $1500+
  • Recalls: None Found

Suspension

• Front Suspension Ball Joint Failure
  • Description/Symptoms: Clunking noise from the front end, especially over bumps. Steering may feel loose or wandering.
  • Solution: Replace worn ball joints.
  • Estimated Cost to Fix: $200 - $500 per side
  • Recalls: None Found
• Leaf Spring Sagging or Breakage
  • Description/Symptoms: Rear end sagging, especially when loaded. Ride quality may be poor. Leaf springs may be visibly cracked or broken.
  • Solution: Replace leaf springs.
  • Estimated Cost to Fix: $400 - $1000+
  • Recalls: None Found

Electrical

• Instrument Cluster Failure
  • Description/Symptoms: Gauges (speedometer, fuel gauge, etc.) may become erratic, stop working altogether, or display incorrect readings.
  • Solution: Replace or repair the instrument cluster.
  • Estimated Cost to Fix: $200 - $600+
  • Recalls: None Found
• Blower Motor Resistor Failure
  • Description/Symptoms: HVAC blower motor only works on certain speeds or not at all.
  • Solution: Replace the blower motor resistor.
  • Estimated Cost to Fix: $50 - $200
  • Recalls: None Found

Exterior

• Rust on Rocker Panels and Quarter Panels
  • Description/Symptoms: Rust forming along the lower edges of the vehicle, particularly the rocker panels and rear quarter panels.
  • Solution: Rust repair, including cutting out rusted metal and welding in new panels, followed by bodywork and paint.
  • Estimated Cost to Fix: $500 - $2000+ (depending on severity)
  • Recalls: None Found

Interior

• Headliner Sagging
  • Description/Symptoms: The fabric headliner begins to detach from the backing board and sag down.
  • Solution: Replace or re-glue the headliner fabric.
  • Estimated Cost to Fix: $150 - $400
  • Recalls: None Found

Summary

The 2002 GMC Yukon XL 2500, while a capable and spacious vehicle, is prone to several age-related issues. Engine problems such as intake manifold leaks and exhaust manifold bolt breakage can be costly to repair, particularly with the 8.1L engine. Transmission issues like harsh shifting and torque converter failure are also common. Suspension components such as ball joints and leaf springs may require replacement due to wear and tear. Electrical issues with the instrument cluster and blower motor resistor are also potential concerns. While some fixes are relatively inexpensive, others, like rust repair and transmission work, can be quite costly. Potential buyers should be aware of these issues and factor them into their purchasing decision.