2002 Chevrolet Monte Carlo Problems: 4 Known Issues
2002 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated October 2026
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2002 Chevrolet Monte Carlo has 4 documented known issues, with 2 rated critical. The most serious are ABS/EBCM Module Failure and Brake Lamp Warning ($300-$900 repair) and Oil onto Hot Exhaust Manifold Can Ignite — 3.8L V6 Monte Carlo Recall 09V116000. Across all issues with published estimates, repair costs range from $150 to $900. DIY maintenance guides at au7o.io.
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All 4 Known Issues
NHTSA Recalls12 recalls
ELECTRICAL SYSTEM:IGNITION
This defect can affect the safe operation of the airbag system. Until this recall is performed, customers should remove all items from their key rings, leaving only the ignition key. The key fob (if applicable), should also be removed from the key ring. General Motors LLC (GM) is recalling certain model year 2005-2009 Buick LaCrosse, 2006-2011 Buick Lucerne, 2000-2005 Cadillac DeVille, 2006-2011 Cadillac DTS, 2006-2014 Chevrolet Impala, and 2006-2007 Chevrolet Monte Carlo vehicles. In the affected vehicles, the weight on the key ring and road conditions or some other jarring event may cause the ignition switch to move out of the run position, turning off the engine.
STEERING
DORMAN IS RECALLING 979 STEERING KNUCKLES, DORMAN P/NOS. 697-902 AND 697-903, SOLD UNDER DORMAN'S "OE SOLUTIONS<SUP>TM</SUP>" BRAND NAME, AND NAPA P/NOS. 7-8502 AND 7-8503 WHICH WERE SOLD FOR REPLACEMENT USE ON THE VARIOUS VEHICLES LISTED ABOVE. A POTENTIAL MATERIAL OR DESIGN DEFECT COULD RESULT IN THE STEERING KNUCKLE BREAKING IN THE HUB AREA.
ELECTRICAL SYSTEM:IGNITION
This defect can affect the safe operation of the airbag system. Until this recall is performed, customers should remove all items from their key rings, leaving only the ignition key. The key fob (if applicable), should also be removed from the key ring. General Motors LLC (GM) notified the agency on July 3, 2014, that they are recalling 5,877,718 model year 2000-2005 Chevrolet Impala and Monte Carlo, 1997-2003 Chevrolet Malibu, 2004-2005 Malibu Classic, 1999-2004 Oldsmobile Alero, 1998-2002 Oldsmobile Intrigue, 1999-2005 Pontiac Grand Am and 2004-2008 Pontiac Grand Prix vehicles. In these models, the weight on the key ring and/or road conditions or some other jarring event may cause the ignition switch to move out of the run position, turning off the engine.
STEERING
DORMAN PRODUCTS IS RECALLING 3,900 INTERMEDIATE STEERING SHAFTS DORMAN PART NOS. 425-151, 425-152, AND 425-153, (SOLD UNDER DORMAN'S "OE SOLUTIONS" BRAND NAME), BALKAMP #'S 7-3057, 7-3058, 7-3059 (SOLD UNDER THE "NAPA" BRAND NAME), AND PLATINUM PARTS #'S 2425151, 2425152, AND 2425153 MANUFACTURED DURING THE MONTH OF SEPTEMBER 2007. THESE REPLACEMENT STEERING SHAFTS CAN BE USED ON THE VEHICLES LISTED ABOVE. THE WELD CONNECTING THE INNER TUBE TO THE OUTER TUBE MAY BE DEFECTIVE.
FUEL SYSTEM, OTHER:STORAGE:TANK ASSEMBLY:PRESSURE RELIEF DEVICES
CERTAIN DELPHI FUEL PRESSURE REGULATORS, P/NOS. FP10020-11B1, FP10026-11B1, AND FP10027-11B1, SOLD AFTER JANUARY 9, 2007, AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES LISTED ABOVE. THE UNIVERSAL PRESSURE REGULATORS (UPR) WERE PRODUCED WITHOUT AN O'RING AND RETAINER.
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Frequently Asked Questions
What are the most common Chevrolet Monte Carlo problems?
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2002 Chevrolet Monte Carlo has 4 documented issues. The most frequently reported are: ABS/EBCM Module Failure and Brake Lamp Warning, Oil onto Hot Exhaust Manifold Can Ignite — 3.8L V6 Monte Carlo Recall 09V116000, 3.8L L36 upper-intake gasket coolant leak — GM 03-06-01-016. Of these, 2 are rated critical and should be addressed promptly.
Is the Chevrolet Monte Carlo reliable?
The 2002 Chevrolet Monte Carlo has 4 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 2 issues are rated critical: ABS/EBCM Module Failure and Brake Lamp Warning and Oil onto Hot Exhaust Manifold Can Ignite — 3.8L V6 Monte Carlo Recall 09V116000. 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 Monte Carlo problems?
Repair costs for known Chevrolet Monte Carlo issues range from $150 to $900, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, ABS/EBCM Module Failure and Brake Lamp Warning, typically costs $300-$900 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
What is the 2000-2007 Chevrolet Monte Carlo ABS/EBCM Module Failure and Brake Lamp Warning?
The Electronic Brake Control Module (EBCM) mounted on the ABS hydraulic unit is prone to failure due to internal solder joint cracking from vibration and thermal cycling. When it fails, ABS, traction control, and stability control all stop functioning. The brake warning light, AB… Repairs typically run $300-$900. Severity: high.
What is the 1998-2003 Chevrolet Monte Carlo Oil onto Hot Exhaust Manifold Can Ignite — 3.8L V6 Monte Carlo Recall 09V116000?
If your 1998-2003 Monte Carlo has the 3.8L naturally aspirated V6, it is named in GM safety recall 09V116000. Hard braking can sling drops of engine oil onto the exhaust manifold. A manifold that is hot enough, combined with oil running down below the heat shield, can start a sma… Severity: high.
What is the 2000-2003 Chevrolet Monte Carlo 3.8L L36 upper-intake gasket coolant leak — GM 03-06-01-016?
GM's May 2004 TechLink identifies coolant loss and milky oil on 2000–2003 Monte Carlo vehicles with the L36 3.8L engine. Its reference to bulletin 03-06-01-016 distinguishes an upper-intake gasket repair from replacing the entire intake assembly. This is not evidence for a coolan… Severity: medium.
What is the 2000-2007 Chevrolet Monte Carlo Power Window Regulator Cable Failure?
The cable-style window regulators in 2000-2007 Monte Carlos fail when the cable stretches, frays, or binds on the reel. The window can drop into the door or become stuck partway. Both front windows are commonly affected. Replacement regulators with added cable guides are an impro… Repairs typically run $150-$500. Severity: low.
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.