What are the most common Chevrolet Silverado 3500HD problems?

According to Au7o's analysis of 430+ owner reports, the 2002-2002 Chevrolet Silverado 3500HD has 2 documented issues. The most frequently reported are: Rear Leaf Spring Breakage Under Load, Glow Plug Failure and Hard Cold Starting. Of these, 1 is rated critical and should be addressed promptly.

Is the Chevrolet Silverado 3500HD reliable?

The 2002-2002 Chevrolet Silverado 3500HD has 2 known issues documented across 430+ owner reports. 1 issue is rated critical: Rear Leaf Spring Breakage Under Load. 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 Silverado 3500HD problems?

Repair costs for known Chevrolet Silverado 3500HD issues range from $200 to $1,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Rear Leaf Spring Breakage Under Load, typically costs $400-$1,000 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

2002 Chevrolet Silverado 3500HD Problems: 2 Issues Every Owner Should Know

2002 model year · 430+ owner reports · Updated April 2026

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According to Au7o's analysis of 430+ owner reports, the 2002 Chevrolet Silverado 3500HD has 2 documented known issues, with 1 rated critical. The most serious is Rear Leaf Spring Breakage Under Load ($400-$1,000 repair). The most commonly reported issue is Glow Plug Failure and Hard Cold Starting with 250 owner reports. Across all issues, repair costs range from $200 to $1,000. DIY maintenance guides at au7o.io.

All 2 Known Issues

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Community Reported

180 owners

On the 2001-2020 Chevrolet Silverado 3500HD, rear leaf springs crack or break under heavy loads or from fatigue. Common on trucks regularly loaded near GVWR. Broken spring can puncture fuel tank or damage brake lines.

Common Symptoms

Rear sag on one side
Clunking over bumps
Truck leans to one side when loaded
Metal scraping noise from rear
Visible cracked spring leaf

How to Fix

Replace broken leaf spring pack. Consider heavy-duty aftermarket springs if truck is regularly loaded. Inspect U-bolts and spring hangers at same time.

What Owners Are Using

Parts and tips from 180+ owners who fixed this issue

TipAdd helper springs or air bags if you regularly load near GVWR to extend leaf spring life
UpgradeComplete strut and shock absorber set for full suspension refresh (KYB Excel-G Strut/Shock Set)
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UpgradeFour-wheel alignment kit with cam bolts for proper tire wear correction (Moog Alignment Cam Bolt Kit)
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Typical repair cost:$400 - $1,000

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180+ owners have reported this issue

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Community Reported

Low Confidence180 reportsLast reported by owners Mar 2026Reviewed Mar 2026

Community Reported

250 owners

On the 2001-2020 Chevrolet Silverado 3500HD 6.6L Duramax, glow plugs fail causing difficult cold weather starting. Can also swell and break during removal, requiring extraction. Glow plug module can also fail.

This issue also affects: GMC Sierra 3500HD, Mercedes-Benz Sprinter

Common Symptoms

Hard starting in cold weather
Extended cranking
White smoke on cold start
Glow plug indicator stays on too long
Rough idle when cold

How to Fix

Replace failed glow plugs. Use penetrating oil and heat to prevent breakage during removal. Replace glow plug controller module if diagnostics indicate module failure.

What Owners Are Using

Parts and tips from 250+ owners who fixed this issue

UpgradeACDelco 60G glow plug is OE replacement for Duramax (ACDelco #60G)
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Typical repair cost:$200 - $800

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250+ owners have reported this issue

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Community Reported

Low Confidence250 reportsLast reported by owners Mar 2026Reviewed Mar 2026

2002 Chevrolet Silverado 3500HD Problems: 2 Issues Every Owner Should Know

All 2 Known Issues

2001-2020 Chevrolet Silverado 3500HD: Rear Leaf Spring Breakage Under Load#

Common Symptoms

How to Fix

What Owners Are Using

Research This Issue

2001-2020 Chevrolet Silverado 3500HD: Glow Plug Failure and Hard Cold Starting#

Common Symptoms

How to Fix

What Owners Are Using

Research This Issue

Other Chevrolet Models

Frequently Asked Questions

What are the most common Chevrolet Silverado 3500HD problems?

Is the Chevrolet Silverado 3500HD reliable?

How much does it cost to fix common Chevrolet Silverado 3500HD problems?

What is the 2001-2020 Chevrolet Silverado 3500HD Rear Leaf Spring Breakage Under Load?

What is the 2001-2020 Chevrolet Silverado 3500HD Glow Plug Failure and Hard Cold Starting?