GMC Yukon XL 2000–2006
Common on this vehicle:Gauge or instrument faultWarning lightCorrosion or rustNoiseLeakReduced brakingStalls or shuts offLoss of engine power, no acceleration
There are 2,120 records on the 2000–2006 GMC Yukon XL (Owner complaint: 983, Recall: 38, Manufacturer communication: 1,099). The documents describe 143 known issues; those with the most records under them are Gauges stick or flutter (138), Brake pipe corrosion (135), ABS activation at low speed (52).
Possible causes
145 causes not drawn
- Voltmeter fluctuates between 12 and 14 volts (Regulated Voltage Control, normal)3
- Hydro-boost brake assist and power steering share one hydraulic supply (four campaigns)19
- Brake pedal moves or self applies at full steering lock (Hydro-Boost)2
- Brake pedal pushrod retainer missing - recall 05V-1031
- Cosmetic brake rotor corrosion: burnish, do not resurface1
- ABS light with C0265/C0201/U1041 or no communication with brake module (EBCM ground G110)1
- Front right-hand brake pipe contact with body cross sill - recall 00V-3451
- DIC “Reduced Brake Power” message and reduced vacuum boost1
- Service Brake Booster message on a Hydroboost vehicle with DTC C0136 (instrument cluster not SPS programmed)1
- Stability System Disabled / Service Stability message with DTC C0455 (bent terminals at the steering wheel position sensor)1
- Violent steering wheel shake or vibration at road speed (brake booster)1
- Brake Rotor: corroded, worn11
- Aftermarket part (not the vehicle as built): Federal-Mogul National / Carquest replacement wheel hub assembly retention nut - recall 07E-1062WD only1
- Grease seen at front hub bearing seals (normal purge, do not replace)1
- Creak or squeak noise from the rear lower control arm bushings (do not replace the propshaft)1
- Upper control arm bracket alignment (dowel) pin missing at front end alignment1
- Vehicle body tilt or lean left / right (torsion bar front suspension)1
- Tire: broken, failed31
- Tire Tread and Belt: broken, failed5
- DTC P0446 set with the SES lamp on (replace the EVAP vent solenoid, not the canister)3
- Fuel pressure regulator buzz / hum after replacement (check fuel pump feed voltage drop and connector crimps)4.8L, 5.3L, 6.0L only2
- Engine fuel rail crossover tube retainer screws may break (5.3L RPO L59) - recall 04V-3765.3L only2
- Engine fuel rail pulse damper retainer clip may fracture (8.1L V8) - recall 06V-289 / Transport Canada 20061958.1L only2
- Slow or short fuel fill, inaccurate fuel gauge (2500: fuel tank vent)2500 only1
- Fuel gauge reads low or drops to empty in Park / Neutral (normal characteristic)1
- Fuel Pump: failed, leaking19
- Fuel Line: broken, leaking2
- Fuel Tank: leaking2
- Driver's seatback moves during braking (recliner replacement)3
- Center console lid hard to open or close (lubricate the latch)2
- RPO DL3 power folding mirror loose, moves or shakes after being folded by hand (cycle it electrically)2
- Door manual lock lever disengages from the door trim panel (lock lever replacement)2
- Bench seat (RPO AE7) center console armrest hinges broken (replace the lid, not the console assembly)1
- Rattle from the center of the dash (cowl insulator clip)1
- Door sags or is hard to open or close (worn or corroded hinge pins and bushings)1
- Front seat adjuster switch knob loose or missing (replace only the switch cover)1
- Headliner or roof rattle (roof drain channel)1
- Broken latch of the rear cupholder in the center console (replace the latch only)1
- Rear door upper hinge welds out of specification (FMVSS 214) - recall 03V-0371
- Side access door noise (door check link replacement)1
- Factory trailer hitch receiver bent, broken or weld failure1
- Liftgate Glass Hinge: broken, loose or misadjusted17
- Rear Window Glass: broken, loose or misadjusted7
- Spare Tire Carrier Winch Cable: broken, corroded4
- Frame: corroded3
- Tire scrub noise on low speed turns (steering rod / centerlink installed backwards)1
- Pitman Arm: design or manufacturing1
- Steering Gear Box: leaking2
- Pitman Arm Shaft Seal: leaking1
- Power Steering Line: corroded1
- Remote keyless entry and front passenger door window, lock, mirror inoperative (reprogram the Passenger Door Module)13
- Reduced Engine Power from throttle body connector crimp, broken wire or grounds7
- Ground Ring Terminal: loose or misadjusted3
- CD slow to play, CHECK CD error, CD stuck or clock resets to 12:00 (reprogram the radio, do not replace it)2
- Rear seat audio and/or rear HVAC controls inoperative (replace the RSA, not the console)2
- Trailer brakes applied whenever headlamps or park lamps are on (brake controller jumper harness)2
- Starter keeps cranking after the key is released (PCM-controlled automatic crank, normal)5.3L only2
- Generator whine in the audio system (new ground for radio and amplifier)1
- Intermittent battery drain from a sticking A/C compressor relay1
- Intermittent battery lamp with history DTC B1489 after BGCM replacement (module not SPS programmed)1
- Intermittent MIL, service lamps/messages or DTCs from connector fretting corrosion1
- Positive battery cable contact with steering shaft universal joint (Denali) - Transport Canada 20010921
- Memory seat recalls to a more-forward position than set (memory seat module software)1
- No audio out of the speakers at times (radio reprogram or amplifier replacement)1
- Poor radio reception from a loose radio antenna mast1
- Radio shows a disc error when a media disc is inserted (unsupported disc format or damaged disc)1
- No audio and no radio display, or radio clock resets (2004; radio set-up with the Tech 2)1
- Red radio theft LED does not flash (manufacturer's counter not reset at assembly)1
- Rear wiper jumps when the fog lamps are turned on (auxiliary ground to rear washer pump)1
- Seat heater or memory power seat inoperative (memory seat control module)1
- Turn signal flashes fast (export flasher relay installed)1
- Hum or fan noise from the navigation radio (internal cooling fan, normal)1
- Radio volume lower at the same setting after reprogramming or replacement (new audio calibration, normal)1
- Replacement headlamp switch has no LED indicators and sets DTC B0951 (2003, normal)1
- Keyless Entry Transmitter: failed5
- Battery: leaking, design or manufacturing3
- Wiring: overheated, broken3
- Intake manifold gasket leak (cold idle misfire, lean codes)11
- Oil leak after cold start from frozen PCV system (rear main seal)6
- Single-cylinder misfire (P0300-P0308) and/or chirp, squeak or tick at camshaft speed: worn cam lobe / lifter, valve or valve spring5
- Engine Block5
- Increased accelerator pedal effort / throttle body sticks (clean and adjust, do not replace)4.8L, 5.3L, 6.0L only4
- Crankshaft position sensor may work intermittently or fail (8.1L V8) - recall 07V-5218.1L only4
- Cylinder4
- Lean hesitation, sag or stumble at -6 to +20°C coolant temperature (PCM reprogram)4.8L, 5.3L, 6.0L only2
- Higher than expected oil consumption at 8600 GVW and above (accepted rate and consumption test)2
- Rear bank knock sensor corrosion from water intrusion (P0332)4.8L, 5.3L, 6.0L only2
- Accessory drive belt whine (power steering pump pulley repositioned)1500 only1
- Castech cylinder head porosity crack (gradual coolant loss)4.8L, 5.3L only1
- Higher than expected engine oil consumption (PCV valve replacement)4.8L, 5.3L, 6.0L only1
- P0300 after engine repairs: injector connectors crossed (cylinders 5-7 / 6-8)1
- Slight roughness at idle with no DTCs (possible characteristic)1
- 4L80-E / 4L85-E planetary gear whine in first and second gear3
- 4L60-E burnt 3-4 clutch pack1
- 4L60-E slip or no forward engagement right after input housing replacement (service part 17803687)1
- Whine noise from the rear axle (tuned torsional damper propeller shaft)1
- Service 4WD indicator and DTC B2725 (transfer case shift control switch)4WD / AWD only1
- 4WD/AWD lamps and system inoperative: "sleepy" New Venture Gear transfer case control module (reprogram the TCCM)4WD / AWD only1
- Transfer case service light, New Venture Gear transfer case (replace the encoder motor sensor and reprogram the TCCM)1
- Electronic transfer case stops shifting with no DTC (shift abuse lock out mode, normal)1
- Transfer case speed sensor connector locks bend on disconnect (improved connector)1
- 4L60-E / 4L65-E clunk on 2-3 upshift or 3-2 downshift (normal condition)1
- Transmission: failed7
- Differential: clogged or contaminated, failed3
- Front Differential: failed2
- HVAC blower motor resistor module / connector overheating5
- Engine compartment noise with A/C on and A/C inoperative (auxiliary rear A/C: suction hose and compressor)3
- No passenger compartment air filter (not available from the 2003 model year; normal)2
- Climate Control Module: electrical fault, software2
- A/C blows warm at extended idle (6.0L: auxiliary electric cooling fan)6.0L only1
- HVAC actuator clicking / ticking noises (recalibrate the HVAC control module, do not replace actuators)1
- Loss of HVAC mode or temperature control (wiring harness rerouted)1
- Passenger side colder or warmer than the driver's side (HVAC case to cowl seal)1
- Insufficient heat from the rear heater in extreme cold (tee coupling replacement)1
- Rear HVAC ticking noise, no rear temperature or mode control, DTC B0434 / B3764 (revised auxiliary HVAC control module)1
- Air Conditioning Compressor: failed2
- Air Conditioning Cycling Switch: failed1
- Air Conditioning Line: corroded1
- OnStar System: failed, software5
- Some OnStar features no longer work (2G cellular sunset; the module is not broken)2
- OnStar cannot configure the vehicle (118 error) after the 15-08-44-001 upgrade1
- No response when the OnStar button is pressed (DTC B2476): button assembly test values1
- Red OnStar LED and DTC B2455 after Canada upgrade bulletin 15-08-44-001 (audio and microphone drain wires shorted)1
- Digital Radio Receiver: failed1
- OnStar Module: electrical fault1
- CD Player: overheated, software2
- OnStar Hardware: software1
- Radio: failed1
- P0420 / P0430 on a new or just-replaced catalytic converter (break-in not completed)4
- Exhaust pop or ping noise (replace the heat shield, not the exhaust system)1
- Purge Solenoid: failed1
- Air bag sensing diagnostic module (SDM) anomaly - recall 02V-1782
- Air bag lamp on with DTC B0092 (passenger presence system sensor harness)1
- AIR BAG indicator on with side impact module DTCs (connector CPA replacement)1
- 2nd/3rd row outboard seat belt retractor internal crack - recall 01V-1591
- Second row seat belt retractor does not lock automatically for a child restraint1
- SIR lamp on and inside mirror temperature/compass display inoperative (open air bag fuse, circuit 1139 shorted to ground)1
- Airbag Sensor: failed2
- Side Impact Module: electrical fault, failed2
- Tire and loading information label lists inaccurate vehicle capacity weight (FMVSS 110) - recall 05V-5521
- Bearing: broken, failed2
- Bolt: broken, loose or misadjusted2
- Seal: failed1
- Radiator: failed2
- Water Pump: failed1
The documents say what to doOnly records name itThe size of a node, the width of a link and the numbers are records matching this search, not likelihoods.
FaultCrate・GMC Yukon XL 2000–2006
Candidate cause (the documents say what to do)
Brake pipe (brake line) corrosion and rupture
The pipes' steel-copper construction is vulnerable to galvanic corrosion if exposed to the environment.
NHTSA found the failures came with general excessive corrosion over most of the pipe assembly and appear to be expected wear-out of the coating in severe-corrosion states.
How to tell
Brake warning / Service Brake System
What to do
- In the joint inspections, scaling or flaking corrosion was taken as indicating the onset of metal loss and given the second lowest ranking (2); a leaking or previously repaired pipe was the lowest (1).
- GM noted that pipes with excessive flaking corrosion can only be fully evaluated, including remaining service life, by removing them, cleaning off the corrosion and sectioning them to assess remaining wall thickness.
- The inspections found no specific location where corrosion was visually more severe and no pattern between vehicles.
- Service records of incident vehicles also indicate that repairs are not isolated to a specific location or brake pipe.
- GM recommends replacing the entire set of pipes whenever any pipe leaks or is corroded enough to need replacement.
- On June 28, 2013 GM released 66 new part numbers for servicing brake pipes in 1999-2007 GMT800 pickups and utility vehicles.
Caution: Analysis of repair records indicates that consumers often elect to repair only the failed circuit.
What is needed
- Parts and materials
- The entire set of brake pipes (whenever any pipe leaks or is corroded enough to need replacement; GM's recommendation)
- GM brake pipe kit (a complete set of pre-formed and pre-flared pipes, for when the entire brake pipe assembly is replaced)
- Labor time
- Kit procedure: 4.5 to 6.0 hours, depending on the vehicle's configuration (labor time guideline of the October 2014 TSB)
- Forming and flaring replacement tubing to fit the vehicle: approximately 8.5 hours (base time estimate)
- Special tools
- Not stated
- Scan tool
- Not stated
Only what the technical documents state. "Not stated" does not mean not needed.
In the records
- Brake Line: replaced 23(result not stated: 23)
- Brake Rotor: replaced 2(result not stated: 2)
- Caliper: replaced 2(says it was fixed: 1, result not stated: 1)
Work that followed
- Brake Line (replaced) did not settle it; then Brake Hose (replaced) 1(says it held for a while: 1)record 1
- Brake Line (replaced) did not settle it; then Caliper (replaced) 1(says it was fixed: 1)record 1
- Master Cylinder (replaced) did not settle it; then Caliper (replaced) 1(says it was fixed: 1)record 1
The course as owners' complaints state it. A complaint is filed more often when a repair did not hold, so the counts are not a rate at which work succeeds.
Outside the documents and the records
Of the four pages read, the Yukon appears only in a single sentence of a post merged into a thread titled for a 2004 Yukon; that post gives neither the poster's vehicle and model year nor how the repair turned out. The others are records on a 2000 Tahoe, a Hummer H2 (model year not given) and the Silverado, and the Silverado thread is questions and advice only, with no repair outcome.
- A record by the owner of a 2000 Tahoe on Car Talk Community and one post merged into a 2CarPros thread titled for a 2004 Yukon (the poster does not state his own vehicle or model year) both say that the brake pipes running toward the rear of the vehicle were replaced. Car Talk Community2CarPros
- Sky Auto writes that on a Hummer H2 (model year not given) the left and right front brake pipes running over the left frame rail had corroded through and were leaking fluid, and that because the part was not supplied, the corroded stretch was cut out and remade from general-purpose brake pipe. スカイオート(埼玉)
- The owner of a 2000 Tahoe (125,000 miles (= 201,168 km)) on Car Talk Community writes that Pep Boys said it could not do the job itself and put the cost at somewhere between $1,500 and $2,000, that the dealer quoted $3,000 (possibly more if further rust turned up, and with the explanation that the steel line has to be made by hand), and that in the end an independent shop replaced the pipes from around the driver's seat rearward and the repair came to $1,600. Car Talk Community
- The same 2000 Tahoe owner writes that the fuel tank had to come down to reach the pipes running over it, and that the fuel lines, which were corroded, also failed when the tank went back in. Car Talk Community
- In a 2CarPros thread titled for a 2002 Silverado, a poster who gives his truck as a 2000 Silverado reports that while he was replacing a rotted pipe from the master cylinder to the ABS unit all of the front pipes above the frame came apart, leaving it unclear which pipe goes to which ABS port. One of the answerers in the same thread writes that looking at the ABS unit with a mirror for a stamped F or R is something to try. 2CarPros
The sentences above were written by FaultCrate from what shops' public pages and Q&A sites state as fact (none of the pages' wording is shown; a second reader checked each against its pages). A record of another vehicle says which vehicle. A Q&A thread is a question and advice, and may not say how the repair ended. The links below are places to look; the contents of pages not read were not checked.
The pages read, and other places to look (11)
Shops' repair records
- ハマーH2 ブレーキパイプ修理スカイオート(埼玉), Hummer H2, 2023
Repair videos
- Chevy Tahoe Suburban / GMC Yukon Brake Line Replacement HighlightsYouTube, Chevy Tahoe / Suburban / GMC Yukon, not read
- 1999-2006 Yukon / Tahoe / Suburban front to rear axle brake line replacement tip!YouTube, Yukon / Tahoe / Suburban 1999-2006, not read
- Chevy brake line replacement GMC Yukon Silverado Suburban Tahoe 2000 /upYouTube, GMC Yukon / Silverado / Suburban / Tahoe 2000 and up, not read
- Rusted out brake lines on Chevy, GMC, Avalanche, Yukon, Tahoe, SuburbanYouTube, Chevy / GMC / Avalanche / Yukon / Tahoe / Suburban, not read
- DIY Brake line replacement 1999-2007 Chevy Silverado 1500 with routing diagram for all 5 solid linesYouTube, Chevy Silverado 1500 1999-2007, not read
- How to Replace Rusted GM brake linesYouTube, no vehicle stated, not read
Forums and Q&A
- 2000 Chevy Tahoe brake linesCar Talk Community, 2000 Chevy Tahoe, 2014
- 2004 Gmc Yukon How Do I Bleed the Brakes2CarPros, 2004 GMC Yukon, 2012
- 2002 Chevrolet Silverado Replacement Brake Lines2CarPros, 2002 Chevrolet Silverado, 2009
- replacing factory steel brake linestahoeyukonforum.com, no vehicle stated, not read
See the evidence (1 technical documents, 135 records)
Passages of the technical documents
NHTSA's investigation covered 1999-2003 GM C/K pickups and SUVs in salt-belt states.
Products: 1999-2003 GM C/K pickup trucks and SUVs in Salt Belt states
NHTSA ODI 2015-04-08
The GMT800 platform includes 1999-2007 Silverado and Sierra 1500, 2500 and 3500 pickup trucks; 2000-2006 Suburban, Tahoe and Yukon; and 2002-2006 Escalade and Avalanche.
The GMT800 platform includes the following vehicles: 1999-2007 Chevrolet Silverado and GMC Sierra 1500, 2500 and 3500 series pick-up trucks; 2000-2006 Chevrolet Suburban, Chevrolet Tahoe and GMC Yukon sport utility vehicles; and 2002-2006 Cadillac Escalade and Chevrolet Avalanche sport-utility vehicles.
NHTSA ODI 2015-04-08
Corroded brake lines may rupture during a brake application, reducing brake effectiveness.
Brake line corrosion may result in rupture during brake application, resulting in reduced brake effectiveness.
NHTSA ODI 2015-04-08
The pipes' steel-copper construction is vulnerable to galvanic corrosion if exposed to the environment.
The steel-copper construction is vulnerable to galvanic corrosion if exposed to the environment.
NHTSA ODI 2015-04-09
A cause or a result a complaint states is the owner’s view or what a dealer told them, not an established fact.
Put together by FaultCrate from public records and technical documents. The cause and the repair are for the workshop to decide with the vehicle in front of it. Counts are records, not failure rates.
Pages by symptom, trouble code and warning display (79)
One page each, only where the technical documents say how to deal with a cause.

