Chevrolet Suburban 2500 fuel pump problems

Filed Dec 30, 2016 · Electrical, Fuel system · 105,000 miles · VA

The vehicle in question is a 1999 chevrolet suburban. The gas gauge read erratically and incorrectly for a number of months. Then the engine died immediately after I parked the vehicle one day and failed to restart. I determined that the fuel pump fuse had blown. A new fuse lasted 30 seconds before blowing in its turn. On removing the gas gauge sender/fuel pump assembly from the gasoline tank, I noticed that two of the wires were fused together. Separating the wires took some effort and revealed that the insulation on both wires had completely abraded where they contacted each other such that the bare wires inside touched each other and shorted out the circuit. The insulation on one of the wires had overheated and partially melted off the wire for a short distance (1/2 inch) from the point of contact. Replacement of the entire fuel pump/gas gauge sender solved the problem. Since the entire unit is located inside the gasoline tank of the vehicle, I am concerned that this short might have caused a spark that would ignite the gasoline in the gasoline tank. In the purple wire photo, one can see how the point of contact with the grey wire abraded the insulation down to the bare wire inside. In the grey wire photo, one can see both a comparable abrasion down to the bare wire and also partial melting of the wire insulation, to the point that additional bare wire showed. The metal wires do not appear to have melted or fused; only the insulation did that. But the insulation melting and fusion, as well as the two safety fuses that blew, argue that the abrasion of the insulation continued until the wires inside came into contact with each other. The entire unit is spring loaded such that it is in contact with both the top and the bottom of the gasoline tank. Since the tank flexes slightly in normal use, the wires flex as well, rubbing each other always.

Filed Sep 15, 2015 · Brakes, Fuel system · 72,000 miles · OH

Tl* the contact owns a 2003 chevrolet suburban 2500. While driving 35 MPH, the contact depressed the brake pedal and it traveled all the way to the floorboard. The contact was able to stop the vehicle. The vehicle was towed to an independent mechanic where they performed an interim repair. The vehicle was taken to an independent mechanic where it was diagnosed that all the brake lines were rusted and needed to be replaced. The contact was also informed by the independent mechanic that the vehicle may need the fuel pump line replaced as well. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was 72,000.

Filed Apr 15, 2015 · Fuel system · 101,544 miles · CA

Fuel was pouring out from the top portion of the fuel tank, on my year 2000 chevrolet suburban 2500 where the line goes into the pump at the tank. There was a serious potential fire hazard from fuel pouring onto the exhaust system while driving. I had a certified service station remove the fuel tank, and perform a smoke test. They found the leak coming from the fuel pump assembly. Replaced fuel pump assembly, and fuel filter as recommended. Reinstalled tank, and road tested for any leaks, none found. Total parts, tax, and labor came to $935.05.

Filed Mar 29, 2013 · Fuel system · 190,000 miles · NH

I have owned my 2001 chevy suburban since january of 2008. I have replaced the fuel pump 3 times and today will be my 4th. I have spent thousands of dollars on the same part over and over. The last time it was replaced my mechanic advised us to keep at least 1/4 tank of gas in the tank which I have tried to do. But even doing this the fuel pump seems to go about every 15 months, just outside the warranty. Its ridiculous, there is no way I should be replacing fuel pumps at this rate.

Filed Dec 17, 2009 · Fuel system · 170,000 miles · WA

My 1995 diesel suburban began running a little rough. One morning just after pulling out of the driveway the engine suddenly surged up to 3000 RPM and jumped forward. Fortunately I was able to control it and coax it back into the driveway without incident or injury. Research with my local diesel expert showed that this was due to a failing injector pump and furthermore it is a known problem with these pumps. The problem is now easily reproduced simply by sitting in the driveway and running the truck. It will start, and then rev to 3000+ RPM on it's own, then back to normal. It will do that a couple of times without warning. Not only is this an expensive repair ($2000 in parts alone) but it is extraordinarily dangerous. Had I been at a stoplight with a pedestrian or another vehicle in front of me and it surged I could have easily killed someone. Considering that this problem was known by my mechanic, the potential safety issues and there is a tsb on this fuel pump (01349a) I am stunned that there has not been a mandatory recall.

Filed Jan 1, 2009 · Fuel system · 9,700 miles · RI

In march of 2008 the vehicle shut down while traveling 70 MPH while towing a boat from the florida keys en route to rhode island. The fuel pump was replaced. In december of 2008 while driving back down to the keys towing a boat, the vehicle shut down again at a speed of 70 MPH. The vehicle has less than 10,000 miles on it. The second fuel pump lasted less than 4,000 miles. This vehicle has put our family and other motorists at severe risk. The last event occurred in a construction zone in a heavily congested area with no break down lane. The vehicle and boat were blocking a major highway exit. Our family (including a newborn) had to immediately vacate the vehicle and climb over a jersey barrier to get to a safer location. This vehicle has proven to be unpredictable and dangerous. At this time the vehicle is in a florida dealership awaiting repair and we live in rhode island.

Filed Oct 27, 2008 · Fuel system · 102,000 miles · MN

I have a 2001 chevy suburban. In regards to gm recall 05027, my vehicle is a 2500 series. I experienced a fuel tank leak. After dealer removed tank they found over heated wiring in the fuel pump module. I appeared to be the same problem as the recall, however they said the recall only covered the 1500 series. I phoned gm and they are looking into it. It didn't sound promising. I hope gm is aware the problem exists in the 2500. I felt fortunate to have avoided a fire as the leak was severe if tank was over 3/4 full. The fuel gauge was also inaccurate. Please forward this information along.

Filed Sep 22, 2008 · Electrical, Fuel system · 85,000 miles · CA

My 2002 chevrolet 2500 suburban 8.1l, has been stalling continuously. It stalls when driving, slow, fast or even at a red light, it doesn't matter. I have had the fuel pump, starter, alternator and batter all replaced. I have read on many sites that I am not the only one with the same vehicle with the same problem.

Filed Aug 15, 2007 · Fuel system · 100,000 miles · GA

I purchased this vehicle new in 2001. On july 20, 2007 on an out of town family/work trip, I refilled the fuel tank and traveled another 88 miles to my final destination, upon arrival I smelled gas, but saw no problems. The next morning I was scheduled to attend and event and went out to start the truck and found a hole in the asphalt driveway, approximately 3 feet in diameter, and discovered fuel leaking from the middle of my truck. I removed the gas tank protective cover and fuel spilled everywhere. I found a local mechanic that traveled to my location, he and 2 others worked all day and found that the lock ring that holds the fuel pump assembly to the tank was only lightly connected. Repairs were made and I traveled back home. 8/13/07 my wife filled the tank 3/4's full and the tank leaked fuel all over again. The fuel is leaking from the tank where the fuel pump assembly is connected.

Filed Jul 1, 2007 · Fuel system · 42,137 miles · MN

Fuel pump wire/connecter overheated melting a small hole in module which caused fuel to leak out. Contacting dealership about recall ,old part is avail.