What are the most common Chevrolet C/K 2500 problems?
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1990-2003 Chevrolet C/K 2500 has 4 documented issues. The most frequently reported are: 6.5L Diesel Injection Pump (PMD/FSD) Failure, Brake Line Corrosion and Rust-Through, In-Tank Fuel Pump Failure. Of these, 2 are rated critical and should be addressed promptly.
Is the Chevrolet C/K 2500 reliable?
The 1990-2003 Chevrolet C/K 2500 has 4 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 2 issues are rated critical: 6.5L Diesel Injection Pump (PMD/FSD) Failure and Brake Line Corrosion and Rust-Through. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
How much does it cost to fix common Chevrolet C/K 2500 problems?
Repair costs for known Chevrolet C/K 2500 issues range from $300 to $2,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, 6.5L Diesel Injection Pump (PMD/FSD) Failure, typically costs $300-$2,500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
What year Chevrolet C/K 2500 is the most reliable?
Reliability varies across model years of the Chevrolet C/K 2500. Based on documented issues, problems are most commonly reported in earlier model years. Au7o recommends checking the specific known issues for your target year before purchasing, and having a pre-purchase inspection performed by a qualified mechanic. Our known issues database covers the 1990-2003 Chevrolet C/K 2500 with 4 documented issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports.
What is the 1994-2000 Chevrolet C/K 2500 6.5L Diesel Injection Pump (PMD/FSD) Failure?
The 6.5L diesel uses a Stanadyne DB2 injection pump with a Pump Mounted Driver (PMD/FSD) electronic module that overheats and fails, causing stalling and no-start conditions. This is the most common failure on 6.5L diesel trucks. Repairs typically run $300-$2,500. Severity: high.
What is the 1999-2003 Chevrolet C/K 2500 Brake Line Corrosion and Rust-Through?
Brake lines on C/K 2500 trucks (and all GMT800 full-size GM trucks from 1999-2003) corrode and rust through, particularly in northern states where road salt is used. NHTSA investigated approximately 6 million vehicles but GM did not issue a recall, calling it a maintenance issue. Repairs typically run $400-$1,500. Severity: high.
What is the 1990-2000 Chevrolet C/K 2500 In-Tank Fuel Pump Failure?
Same fuel pump failure issue as the C/K 1500. The dual-tank equipped models have an additional failure point with the tank selector valve which can cause fuel starvation. Repairs typically run $400-$900. Severity: medium.
What is the 1996-2000 Chevrolet C/K 2500 NP241/NP246 Transfer Case Chain Stretch?
The NP241 and NP246 transfer cases used in 4WD C/K 2500 trucks develop chain stretch over time, typically after 160,000-200,000 miles. The stretched chain causes popping noises under load, delayed 4WD engagement, and eventual 4WD failure. The NP246 Auto-Trac version is more probl… Repairs typically run $400-$1,500. Severity: medium.
