2000 model year · 0+ owner reports · Updated April 2026
According to Au7o's analysis of 0+ owner reports, the 2000 Chevrolet C/K 2500 has 4 documented known issues, with 2 rated critical. The most serious are Brake Line Corrosion and Rust-Through ($400-$1,500 repair) and 6.5L Diesel Injection Pump (PMD/FSD) Failure ($300-$2,500 repair). Across all issues, repair costs range from $300 to $2,500. DIY maintenance guides at au7o.io.
On the 1999-2003 Chevrolet C/K 2500, 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. Brake lines run along the frame rail and corrode under securing clips where moisture is trapped.
Parts and tips from 0+ owners who fixed this issue
On the 1994-2000 Chevrolet C/K 2500 6.5L Diesel, 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.
Confirm PMD/FSD failure by checking for stall/no-start when hot, verifying power/ground at the injection pump, and scanning for related OBD-I/OBD-II diesel fault codes; a known-good remote-mounted PMD test module is often the quickest confirmation. Replace the failed PMD/FSD with a quality updated module and calibration resistor, then relocate it from the pump to a heat-sink mounted in a cooler area (commonly behind the bumper or grille) using an extension harness to prevent repeat overheating. Inspect and clean injection pump connectors, grounds, and the engine harness during the repair, because poor connections can mimic PMD failure. Parts typically run about $150-$350 for a PMD kit with heat sink and harness, while complete repair cost is usually $250-$600 depending on labor and whether additional wiring repairs are needed.
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On the 1996-2000 Chevrolet C/K 2500, 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 problematic due to its encoder motor and clutch pack design.
Parts and tips from 0+ owners who fixed this issue
On the 1990-2000 Chevrolet C/K 2500, 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.
Confirm the fault by checking fuel pressure at the TBI or CPI rail and verifying pump power/ground at the tank connector; low or unstable pressure, especially under load, usually indicates a failing in-tank pump or restricted strainer. Replace the in-tank fuel pump module, sock/strainer, and fuel filter, and inspect the tank wiring connector for heat damage; on dual-tank trucks, also test the tank selector valve for proper switching and fuel flow because a failed valve can mimic pump failure and cause starvation. If one tank reads incorrectly or the gauge is erratic, inspect the sending unit while the tank is down and replace it if worn. Typical repair cost is about $350-$900 for a single pump job, or $500-$1,200+ on dual-tank models if the selector valve or both sending units need service.
Parts and tips from 0+ owners who fixed this issue
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According to Au7o's analysis of 0+ owner reports, the 2000-2000 Chevrolet C/K 2500 has 4 documented issues. The most frequently reported are: Brake Line Corrosion and Rust-Through, 6.5L Diesel Injection Pump (PMD/FSD) Failure, NP241/NP246 Transfer Case Chain Stretch. Of these, 2 are rated critical and should be addressed promptly.
The 2000-2000 Chevrolet C/K 2500 has 4 known issues documented across 0+ owner reports. 2 issues are rated critical: Brake Line Corrosion and Rust-Through and 6.5L Diesel Injection Pump (PMD/FSD) Failure. 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.
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, Brake Line Corrosion and Rust-Through, typically costs $400-$1,500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
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.
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.
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.
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.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.
