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GMC Yukon 2000–2006

GMC YukonModel years 2000–2006

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The vehicle (where a record says)

A record is under an engine, a drive or a series only where it says so: the characters of the vehicle identification number filed with a complaint, its text, or what its document says it applies to. A record that does not say is kept as "not stated". The filed numbers and the documents do not tell 4WD from AWD.

Common on this vehicle:NoiseWarning lightLeakVibration or shudderLoss of engine power, no accelerationShifting faultCorrosion or rustGauge or instrument fault

Record by record

80 records state a cause or a remedy. Each record is shown as short labels in the order fault → finding the cause → correction. Press a label to narrow to the records that state it.

Symptom

Component named as the cause

Work done

How it is said to have ended

  • says it came back2
  • says it did not fix it3
  • result not stated2

A ribbon is as wide as the records that state both of its ends (only the commonest are drawn). A record that names several symptoms or components runs through each. Orange is records that say the fault came back or was not fixed. Results come from owners’ reports only; one that does not say is “result not stated”. None of this is a likelihood of a cause or a rate at which work succeeds.

Read the records one by one (34)

Known issues4L60-E burnt 3-4 clutch pack1

  1. Manufacturer communication2003–2006 GMC YUKON ・ 2007-02-22

    Slip Condition in 2nd, 3rd, or 4th Gear Clutch Issue

    1. 1Fault

      Not stated

    2. 2Finding the cause

      Not stated

    3. 3Correction

      SLIP CONDITION IN 2ND, 3RD, OR 4TH. DAMAGED 2-4 OR 3-4 CLUTCH. *KB UPDATED 10/31/07. *NJ

      What the documents say to do

      4L60-E burnt 3-4 clutch pack

      Confirm

      • Test the 3rd accumulator checkball capsule for leakage; a leaking capsule is a leading cause of 3-4 clutch failure.

      Repair

      • Thicker heavy-duty backing plates that eliminate clutch pack flex are available in the aftermarket.

      Caution

      • An obvious leak such as a cracked apply piston should not stop further investigation.
    Read the sentences of the record
    Remedy
    SLIP CONDITION IN 2ND, 3RD, OR 4TH. DAMAGED 2-4 OR 3-4 CLUTCH. *KB UPDATED 10/31/07. *NJ

Known issues4L60-E slip or no forward engagement right after input housing replacement (service part 17803687)1

  1. Manufacturer communication2000–2006 GMC YUKON DENALI ・ 2017-08-15

    Input Housing Inspection for Forward Range Slip

    1. 1Fault

      • A few transmissions may slip or have no engagement in any forward gear immediately after the Input Housing (621) is replaced.

    2. 2Finding the cause

      Possible causes

      • The Input Housing (621) from GM Service Parts may have an incorrectly drilled input shaft.

      Steps to confirm (in the document’s order)

      1. With the Input Housing (621) completely assembled, apply regulated compressed air to the 3-4 clutch feed hole and the forward clutch feed hole one at a time.
      2. Air should not leak out of the 3-4 clutch feed hole when air is applied to the forward clutch feed hole, and not out of the forward clutch feed hole when air is applied to the 3-4 clutch feed hole.

    3. 3Correction

      Repair

      • If air leaks between the two feed holes, replace the Input Housing (621) with one from GM Service Parts, ordering new housing part number 19125752.

      Part numbers printed in the document

      The numbers are as the document prints them. The name and the replacing number are what the pages of GMPartsGiant, a reseller of genuine parts and not GM, state. Aftermarket equivalents are not checked here (the links only search by number). Confirm the fit for the vehicle (VIN) before ordering.

      Parts

      • Part number 19125752, Input Housing And Turbine Shaft Assembly, quantity 1.

      Part numbers printed in the document

      The numbers are as the document prints them. The name and the replacing number are what the pages of GMPartsGiant, a reseller of genuine parts and not GM, state. Aftermarket equivalents are not checked here (the links only search by number). Confirm the fit for the vehicle (VIN) before ordering.

      Caution

      • This information only applies to Input Housing (621) with service part number 17803687; it does not apply to GM service transmission assemblies or original equipment transmission assemblies.
      • When testing a fully assembled housing, a small amount of air leaking between the input shaft and the housing does not indicate a defective part.
      • Do not replace an Input Housing (621) assembly solely because of a small air leak between the shaft and housing.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：The model list includes the 1999-2006 GMC Savana, Sierra, Yukon and Yukon XL.
    • Applies to：It applies to vehicles equipped with the 4L60E, 4L65E or 4L70E automatic transmission (RPO M30, M32 or M70) and service input housing part number 17803687.
    • Caution：This information only applies to Input Housing (621) with service part number 17803687; it does not apply to GM service transmission assemblies or original equipment transmission assemblies.
    • Condition：A few transmissions may slip or have no engagement in any forward gear immediately after the Input Housing (621) is replaced.
    • Cause：The Input Housing (621) from GM Service Parts may have an incorrectly drilled input shaft.
    • Confirm：With the Input Housing (621) completely assembled, apply regulated compressed air to the 3-4 clutch feed hole and the forward clutch feed hole one at a time.
    • Confirm：Air should not leak out of the 3-4 clutch feed hole when air is applied to the forward clutch feed hole, and not out of the forward clutch feed hole when air is applied to the 3-4 clutch feed hole.
    • Repair：If air leaks between the two feed holes, replace the Input Housing (621) with one from GM Service Parts, ordering new housing part number 19125752.
    • Caution：When testing a fully assembled housing, a small amount of air leaking between the input shaft and the housing does not indicate a defective part.
    • Caution：Do not replace an Input Housing (621) assembly solely because of a small air leak between the shaft and housing.
    • Parts：Part number 19125752, Input Housing And Turbine Shaft Assembly, quantity 1.

    Open the manufacturer’s document (PDF) ↗ The points above were read from this document.

    Remedy
    This Preliminary Information communication provides information to the technician about vehicles that have slip in forward ranges immediately after replacing the input housing. Technician will inspect the 3-4 clutches and the forward clutch oil feed passages for leakage between circuits. Technician should apply regulated compressed air to the 3-4 clutch feed hole and the forward clutch feed hole one at a time with the input housing. Technician will need to replace the input housing if there is an air leak 3-4 clutches.

Known issues4L80-E / 4L85-E planetary gear whine in first and second gear1

  1. Manufacturer communication2000–2006 GMC YUKON DENALI ・ 2017-08-15

    Planetary Gear Whine Noise in First and Second Gear

    1. 1Fault

      • The 4L80E/4L85E automatic transmission may have a planetary gear whine noise in first and second gear, typically louder in first gear than in second.

    2. 2Finding the cause

      Steps to confirm (in the document’s order)

      1. If the noise is judged abnormal and the transmission was built after 9-01-03, perform the Rear Unit End Play Check (SI Document ID # 52027).
      2. The correct end play is between 0.127-0.508 mm (0.005-0.020 in).

    3. 3Correction

      Repair

      1. If end play is out of specification, inspect and replace the output planetary gear set (661 - Output Carrier Assembly and 650 - Sun Gear) as necessary.
      2. Set the rear end play with the correct selective thrust washer (674), targeting between .010 and .015 in.
      3. If end play is within specification, replace the transmission assembly, referring to bulletin 02-07-30-029A before ordering it.

      Caution

      • This planetary gear whine can be characteristic of the 4L80E/4L85E; compare the vehicle with an identically built vehicle (same GVWR) before attempting any repairs.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：Applies to 1999-2007 GMC Sierra and Yukon XL (among other listed GM trucks and vans) with the 4L80E (RPO MT1) or 4L85E (RPO MN8) transmission (note: the Yukon XL range runs to 2007).
    • Condition：The 4L80E/4L85E automatic transmission may have a planetary gear whine noise in first and second gear, typically louder in first gear than in second.
    • Caution：This planetary gear whine can be characteristic of the 4L80E/4L85E; compare the vehicle with an identically built vehicle (same GVWR) before attempting any repairs.
    • Confirm：If the noise is judged abnormal and the transmission was built after 9-01-03, perform the Rear Unit End Play Check (SI Document ID # 52027).
    • Confirm：The correct end play is between 0.127-0.508 mm (0.005-0.020 in).
    • Repair：If end play is out of specification, inspect and replace the output planetary gear set (661 - Output Carrier Assembly and 650 - Sun Gear) as necessary.
    • Repair：Set the rear end play with the correct selective thrust washer (674), targeting between .010 and .015 in.
    • Repair：If end play is within specification, replace the transmission assembly, referring to bulletin 02-07-30-029A before ordering it.

    Open the manufacturer’s document (PDF) ↗ The points above were read from this document.

    Remedy
    This Preliminary Information communication provides information to the technician about vehicles that may have a planetary gear whine noise in first and second gear. Technician should compare the noise to a like vehicle. Technician will need to check the build date of the transmission, if it was built after 09/01/2003 and it is determined that a vehicle has an abnormal amount of noise, perform the rear unit end play check. Technician will replace the output planetary gear set if end play is out of specification. The transmission assembly will need to be replaced if the end play is with in specification.

Known issuesGrind / ratchet noise when shifting into Park in 4LO (characteristic)1

  1. Manufacturer communication2000–2006 GMC YUKON DENALI ・ 2018-08-20

    Light Duty Trucks: Grinding Noise in Park with 4WD Low

    1. 1Fault

      • Light duty trucks with automatic transmission and 4 wheel drive may make a grinding/ratcheting noise when the transmission is shifted into park while the transfer case is in 4 wheel drive low (4LO) range.
      • The grind/ratchet noise lasts approximately one second.

    2. 2Finding the cause

      Possible causes

      • When the transmission is shifted from drive or reverse into park with the transfer case in 4LO, the driveline unloads and turns the propeller shaft approximately 1/8 of a turn.
      • The gear reduction in the transfer case makes the transmission output shaft turn faster than the parking pawl will hold, so the parking pawl grinds/ratchets until the output shaft stops.

    3. 3Correction

      Caution

      • This should be considered characteristic of 4 wheel drive vehicles operated in 4LO.
      • Replacing transmission, transfer case and/or driveline components will not resolve the concern; shifting into park with the transfer case in the 4HI or 2HI range is recommended.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：The model list names GMC Yukon models, 1999 - 2019.
    • Condition：Light duty trucks with automatic transmission and 4 wheel drive may make a grinding/ratcheting noise when the transmission is shifted into park while the transfer case is in 4 wheel drive low (4LO) range.
    • Cause：When the transmission is shifted from drive or reverse into park with the transfer case in 4LO, the driveline unloads and turns the propeller shaft approximately 1/8 of a turn.
    • Cause：The gear reduction in the transfer case makes the transmission output shaft turn faster than the parking pawl will hold, so the parking pawl grinds/ratchets until the output shaft stops.
    • Condition：The grind/ratchet noise lasts approximately one second.
    • Caution：This should be considered characteristic of 4 wheel drive vehicles operated in 4LO.
    • Caution：Replacing transmission, transfer case and/or driveline components will not resolve the concern; shifting into park with the transfer case in the 4HI or 2HI range is recommended.

    Open the manufacturer’s document (PDF) ↗ The points above were read from this document.

    Remedy
    This Preliminary information communicates to the dealer technician thatLight Duty Trucks equipped with automatic transmissions and 4 wheel drive may exhibit a condition of grinding/ratcheting type noise when shifting the automatic transmission into park while the transfer case is in 4 wheel drive low (4LO) range. Dealers technician's are advised this condition should be deemed a normal characteristic of 4WD low operation.

Known issuesSingle-cylinder misfire (P0300-P0308) and/or chirp, squeak or tick at camshaft speed: worn cam lobe / lifter, valve or valve spring1

  1. Manufacturer communication2000–2006 GMC YUKON DENALI ・ 2017-08-15

    Service Engine Soon Lamp, Misfire, and Engine Noise Information

    1. 1Fault

      • With the SES light on, a P0300-P0308 DTC is found with misfires counting on a single cylinder that may or may not be felt.
      • A verified noise is not eliminated by canceling fuel injectors and occurs at camshaft speed (half of crankshaft speed); it may be a chirp, squeak, squeal or tick and may increase off idle.

    2. 2Finding the cause

      Possible causes

      • When SI diagnosis does not isolate the cause, it may be a worn camshaft lobe and/or lifter roller, a sticking valve, valve leakage, a broken valve spring, or a collapsed AFM (Active Fuel Management) lifter.

      Steps to confirm (in the document’s order)

      1. During the noise, press with a wooden hammer handle on the valve side, push rod side and side of each rocker arm; if pressure on the valve side changes the noise, it is most likely a lifter and/or cam lobe concern on that cylinder.
      2. Measure cam lobe lift at the push rod side of the rocker arm and compare with other rockers on the same bank; the misfiring or ticking cylinder should have clearly less lift if a lifter roller and/or cam lobe is worn.
      3. A good indicator of a sticking valve is misfires that continue to count on an aggressive deceleration with engine braking.
      4. For a suspected sticking valve, snap the valve onto its seat and confirm it comes off easily; if force is needed to tap it off the seat, excessive carbon build up exists, which may be repaired by decarboning the engine.
      5. The Cylinder Leakage Test outlined in SI should isolate valve leakage by finding excessive leakage past an intake or exhaust valve compared with the others.
      1 more points

    3. 3Correction

      Repair

      • If a worn camshaft lobe or lifter roller is found, replace the camshaft and all lifters per SI, and also replace the plastic lifter guide for the lifter that had the damage.

      Caution

      • A worn cam lobe is easy to overlook through the lifter bores, and unworn lifter rollers do not mean the related cam lobes are okay; both must be carefully inspected.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：The model list names 1999-2013 GMC Savana, Sierra and Yukon with a V8 engine.
    • Condition：With the SES light on, a P0300-P0308 DTC is found with misfires counting on a single cylinder that may or may not be felt.
    • Condition：A verified noise is not eliminated by canceling fuel injectors and occurs at camshaft speed (half of crankshaft speed); it may be a chirp, squeak, squeal or tick and may increase off idle.
    • Cause：When SI diagnosis does not isolate the cause, it may be a worn camshaft lobe and/or lifter roller, a sticking valve, valve leakage, a broken valve spring, or a collapsed AFM (Active Fuel Management) lifter.
    • Confirm：During the noise, press with a wooden hammer handle on the valve side, push rod side and side of each rocker arm; if pressure on the valve side changes the noise, it is most likely a lifter and/or cam lobe concern on that cylinder.
    • Confirm：Measure cam lobe lift at the push rod side of the rocker arm and compare with other rockers on the same bank; the misfiring or ticking cylinder should have clearly less lift if a lifter roller and/or cam lobe is worn.
    • Confirm：A good indicator of a sticking valve is misfires that continue to count on an aggressive deceleration with engine braking.
    • Confirm：For a suspected sticking valve, snap the valve onto its seat and confirm it comes off easily; if force is needed to tap it off the seat, excessive carbon build up exists, which may be repaired by decarboning the engine.
    • Confirm：The Cylinder Leakage Test outlined in SI should isolate valve leakage by finding excessive leakage past an intake or exhaust valve compared with the others.
    • Confirm：A broken valve spring may stay stacked together and be hard to see, so lightly push on different places on the springs with a small hammer handle.
    • Repair：If a worn camshaft lobe or lifter roller is found, replace the camshaft and all lifters per SI, and also replace the plastic lifter guide for the lifter that had the damage.
    • Caution：A worn cam lobe is easy to overlook through the lifter bores, and unworn lifter rollers do not mean the related cam lobes are okay; both must be carefully inspected.

    Open the manufacturer’s document (PDF) ↗ The points above were read from this document.

    Remedy
    This Preliminary Information communication provides information to the technician about vehicles that have a Service Engine Soon Malfunction Indicator Lamp on, engine misfire, and/or engine noise. Technician may find Diagnostic Trouble Codes P0300-P0308. If published Service Information diagnostics does not isolate the cause of this concern technician should check for a worn camshaft lobe and/or lifter roller, a sticking valve, valve leakage, a broken valve spring, and a collapsed active fuel management lifter.

POWER TRAIN20

  1. Owner complaint2003 GMC YUKON DENALI ・ 2012-02-12

    Loss of power without warning while driving at highway speed

    1. 1Fault

      WE WERE DRIVING AT HIGHWAY SPEED AND LOST POWER WITH NO WARNING.

    2. 2Finding the cause

      WITHOUT CLEANING THE THROTTLE BODY OTHERS WILL HAVE THIS PROBLEM TOO.

    3. 3Correction

    Read the sentences of the record
    Fault
    WE WERE DRIVING AT HIGHWAY SPEED AND LOST POWER WITH NO WARNING.
    Cause
    WITHOUT CLEANING THE THROTTLE BODY OTHERS WILL HAVE THIS PROBLEM TOO.
    Remedy
    THE DEALER HAD TO CLEAN THE THROTTLE BODY.
    Consequence
    I COASTED TO THE SIDE OF THE HIGHWAY AVOIDING ONE COLLISION.

  2. Owner complaint2003 GMC YUKON ・ 2006-01-03

    Screeching noise from rear during turns and four-wheel drive engagement

    1. 1Fault

    2. 2Finding the cause

      THIS COULD POSSIBLY BE THE CULPRIT OF THE SCREECHING NOISE WHEN TURNING.

    3. 3Correction

    Read the sentences of the record
    Fault
    DT: THE CONTACT STATED WHEN MAKING TURNS THERE WAS A SCREECHING NOISE COMING FROM THE REAR OF THE VEHICLE. (1 more)
    Cause
    THIS COULD POSSIBLY BE THE CULPRIT OF THE SCREECHING NOISE WHEN TURNING.
    Remedy
    THE DEALER OVERHAULED THE FOUR WHEEL DRIVE, BUT NOTED ALL FOUR TIRES WERE OFF BALANCE AND VARIED IN SIZE. (1 more)

  3. Manufacturer communication2000–2006 GMC YUKON DENALI ・ 2024-08-15

    Transmission Core Damage Prevention Notice

    1. 1Fault

      • GM is receiving many cracked or broken transmission cores at the remanufacturing facilities, and the damage makes them unusable for remanufacturing.

    2. 2Finding the cause

    3. 3Correction

      GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the dealers to be more careful not to damage the transmissions during removal and to package the core properly for return.

    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：Applies to 2000 to 2024 GM passenger cars, SUVs and light/medium duty trucks.
    • Condition：GM is receiving many cracked or broken transmission cores at the remanufacturing facilities, and the damage makes them unusable for remanufacturing.

    Open the manufacturer’s document (PDF) ↗ The points above were read from this document.

    Remedy
    GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the dealers to be more careful not to damage the transmissions during removal and to package the core properly for return.

  4. Manufacturer communication2000–2006 GMC YUKON ・ 2022-10-17

    Torque Converter Bolt Removal Warning

    1. 1Fault

      • Noise from underneath a vehicle equipped with an automatic transmission.

    2. 2Finding the cause

      Possible causes

      • Running the engine with those bolts removed may damage the pilot on the front of the torque converter, the pilot hole in the end of the crankshaft, or both.

      Steps to confirm (in the document’s order)

      • Use chassis ears to isolate the component or assembly that is the loudest source of the noise.

    3. 3Correction

      Caution

      • Do not remove the flex plate to torque converter bolts, push the converter back toward the transmission and start the engine to tell whether the noise is from the engine or the transmission.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：All brands and models, model years 2000 - 2021.
    • Condition：Noise from underneath a vehicle equipped with an automatic transmission.
    • Caution：Do not remove the flex plate to torque converter bolts, push the converter back toward the transmission and start the engine to tell whether the noise is from the engine or the transmission.
    • Cause：Running the engine with those bolts removed may damage the pilot on the front of the torque converter, the pilot hole in the end of the crankshaft, or both.
    • Confirm：Use chassis ears to isolate the component or assembly that is the loudest source of the noise.

    Open the manufacturer’s document (PDF) ↗ The points above were read from this document.

    Remedy
    This Preliminary Information communication provides information to the technician to not remove the torque converter bolts and start the engine as this may cause damage to the torque converter of the crankshaft on vehicles equipped with an automatic transmission.

  5. Owner complaint2003 GMC YUKON ・ 2022-10-06

    Engine stalls with battery warning light and brake pedal vibration at various speeds

    1. 1Fault

    2. 2Finding the cause

      Not stated

    3. 3CorrectionNot repaired

      The vehicle had yet to be repaired.

    Read the sentences of the record
    Fault
    The contact stated that while driving at various speed, the vehicle would stall as the battery warning light appeared on the instrument panel. (1 more)
    Remedy
    The vehicle had yet to be repaired.

  6. Manufacturer communication2000–2006 GMC YUKON DENALI ・ 2022-09-19

    Flexplate and Torque Converter Separation Warning

    1. 1Fault

      • A noise comes from underneath a vehicle equipped with an automatic transmission.
      • The technician may find that the noise comes from the bell housing area.

    2. 2Finding the cause

      Possible causes

      • Running the engine with those bolts removed may damage the pilot on the front of the torque converter, the pilot hole in the end of the crankshaft, or both.

      Steps to confirm (in the document’s order)

      • Use chassis ears to isolate the component or assembly that is the loudest source of the noise.

    3. 3Correction

      Caution

      • Do not separate the torque converter from the flex plate.
      • Do not remove the flex plate to torque converter bolts, push the converter back and start the engine to tell whether the noise is from the engine or the transmission.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：Applies to GM passenger cars and trucks, model years 2000 to 2023.
    • Condition：A noise comes from underneath a vehicle equipped with an automatic transmission.
    • Condition：The technician may find that the noise comes from the bell housing area.
    • Caution：Do not separate the torque converter from the flex plate.
    • Caution：Do not remove the flex plate to torque converter bolts, push the converter back and start the engine to tell whether the noise is from the engine or the transmission.
    • Cause：Running the engine with those bolts removed may damage the pilot on the front of the torque converter, the pilot hole in the end of the crankshaft, or both.
    • Confirm：Use chassis ears to isolate the component or assembly that is the loudest source of the noise.

    Open the manufacturer’s document (PDF) ↗ The points above were read from this document.

    Remedy
    This diagnostic tip advises the tech not to separate the flexplate from the torque convertor or damage my occur if the engine is started while diagnosing for noise from the engine or transmission.

  7. Manufacturer communication2000–2006 GMC YUKON DENALI ・ 2017-08-15

    American Axle Manufacturing Axle Setup Information

    1. 1Fault

      Not stated

    2. 2Finding the cause

      Steps to confirm (in the document’s order)

      1. If the measured pinion shim comes out near either end of the range, compare it with the shim that was removed or recheck the setup of the measuring tools.
      2. To verify side bearing preload, the total torque to turn at the pinion should rise 5 - 10 in. lbs (= 0.565–1.13 N·m) after the differential case is installed.
      3. Axle shaft end play specification is 0.012 inch (= 0.305 mm) per side; radial (up and down) is 0.002 - 0.003 inch (= 0.0508–0.0762 mm).

    3. 3Correction

      Repair

      1. On an 8.6 axle the pinion shim used or stacked behind the pinion is 0.050 inch (= 1.27 mm) at most and 0.020 inch (= 0.508 mm) at least.
      2. Set backlash to 0.003 to 0.005 inch (= 0.0762–0.127 mm) on a new ring and pinion for any AAM application, and check the gear pattern.
      3. Rule of thumb for an 8.6 inch (= 218.4 mm) axle with a 5 cut gear set: use a 0.035 inch (= 0.889 mm) pinion shim and set backlash to 0.004 inch (= 0.102 mm).
      4. Use backlash to move the pattern heel to toe, and the pinion shim to move the pattern height (crest to root).
      5. Drive pinion bearing preload is 15 - 30 in. lbs (= 1.69–3.39 N·m) with new bearings; with old bearings, check the rolling torque before disassembly and reset to only 3 - 5 in. lbs (= 0.339–0.565 N·m) above the original.
      1 more points

      Caution

      • A ring and pinion can be reused or adjusted only below 500 miles (= 804.7 km) and only if not used for towing; if the vehicle has towed anything, the gear set must be replaced.
      • A "roller coaster" or "hourglass" pattern on the bearings may be normal up to 10,000 miles (= 16,093 km) and possibly longer, because the bearings have not fully broken in.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：Applies to 1999-2013 GM light duty trucks and utilities.
    • Repair：On an 8.6 axle the pinion shim used or stacked behind the pinion is 0.050 inch (= 1.27 mm) at most and 0.020 inch (= 0.508 mm) at least.
    • Confirm：If the measured pinion shim comes out near either end of the range, compare it with the shim that was removed or recheck the setup of the measuring tools.
    • Repair：Set backlash to 0.003 to 0.005 inch (= 0.0762–0.127 mm) on a new ring and pinion for any AAM application, and check the gear pattern.
    • Caution：A ring and pinion can be reused or adjusted only below 500 miles (= 804.7 km) and only if not used for towing; if the vehicle has towed anything, the gear set must be replaced.
    • Caution：A "roller coaster" or "hourglass" pattern on the bearings may be normal up to 10,000 miles (= 16,093 km) and possibly longer, because the bearings have not fully broken in.
    • Repair：Rule of thumb for an 8.6 inch (= 218.4 mm) axle with a 5 cut gear set: use a 0.035 inch (= 0.889 mm) pinion shim and set backlash to 0.004 inch (= 0.102 mm).
    • Repair：Use backlash to move the pattern heel to toe, and the pinion shim to move the pattern height (crest to root).
    • Repair：Drive pinion bearing preload is 15 - 30 in. lbs (= 1.69–3.39 N·m) with new bearings; with old bearings, check the rolling torque before disassembly and reset to only 3 - 5 in. lbs (= 0.339–0.565 N·m) above the original.
    • Confirm：To verify side bearing preload, the total torque to turn at the pinion should rise 5 - 10 in. lbs (= 0.565–1.13 N·m) after the differential case is installed.
    • Repair：Use a new pinion nut whenever the old one is removed; never reuse a used nut.
    • Confirm：Axle shaft end play specification is 0.012 inch (= 0.305 mm) per side; radial (up and down) is 0.002 - 0.003 inch (= 0.0508–0.0762 mm).

    Open the manufacturer’s document (PDF) ↗ The points above were read from this document.

    Remedy
    This Preliminary Information communication provides information to the technician with the axel setup information from American Axle Manufacturing. Technician should be advised that the maximum pinion shim to be used or stacked behind the pinion is 0.050?, and the minimum pinion shim is 0.020? for an 8.6 axle. The range for available pinion depth shims for the 10.5? axle is 0.006? to 0.024?. When setting the backlash it should be set between 0.003? to 0.005? on a new ring and pinion for any American Axle Manufacturing application. The ring and pinion can be reused or adjusted if the mileage is less than 500 miles (= 804.7 km), if not used for towing. Technician should be advised that a ?roller coaster? or ?hourglass? pattern on the bearings may be normal up to 10,000 miles (= 16,093 km) and possibly longer. With a mis-machined housing you may get a heel pattern on both sides of the gear teeth at build up can generally be corrected with backlash adjustments. When setting up an 8.6? axle with a 5 cut gear set is to use a 0.035? pinion shim and set backlash to 0.004?. When using the newer 2 cut gear set also use a 0.035? pinion shim and still set backlash to 0.004?. To set the gear pattern use backlash to adjust the pattern heel to toe. Use the pinion shim to adjust the height of the pattern. The proper drive pinion bearing pre-load is from 15 - 30 inch pounds (= 1.69–3.39 N·m) with new bearings. The total torque to turn after the differential case is installed should increase 5 - 10 inch pounds (= 0.565–1.13 N·m) at the pinion. A new pinion nut must be used whenever the old one is removed. The axle shaft end play specification is 0.012? per side and the radial specification is 0.002? - 0.003?. Technician should be advised that synthetic lube can be used in all new American Axle Manufacturing axle assemblies. The new pinion seal for the 8.6? axle assembly is a two piece design.

  8. Manufacturer communication2000–2006 GMC YUKON ・ 2008-12-18

    GMC: Transmission oil cooler line fluid leak (2000-2006)

    1. 1Fault

    2. 2Finding the cause

    3. 3Correction

      GMC: FLUID LEAK FROM TRANSMISSION OIL COOLER LINES DUE TO CORROSION. ALL 2000-2006 LIGHT DUTY TRUCKS EQUIPPED WITH THE LIGHT DUTY AUTOMATIC TRANSMISSION. *PE

    Read the sentences of the record
    Remedy
    GMC: FLUID LEAK FROM TRANSMISSION OIL COOLER LINES DUE TO CORROSION. ALL 2000-2006 LIGHT DUTY TRUCKS EQUIPPED WITH THE LIGHT DUTY AUTOMATIC TRANSMISSION. *PE

  9. Manufacturer communication2000–2006 GMC YUKON DENALI ・ 2008-04-07

    Eaton Locking Differential Chatter Shudder Noise on Turns (RPO G80)

    1. 1Fault

    2. 2Finding the cause

    3. 3Correction

      EATON LOCKING DIFFERENTIAL CHATTER SHUDDER NOISE ON TURNS, EQUIPPED WITH A LOCKING REAR DIFFERENTIAL RPO G80. *NJ UPDATED 7/17/2008. *PE

    Read the sentences of the record
    Remedy
    EATON LOCKING DIFFERENTIAL CHATTER SHUDDER NOISE ON TURNS, EQUIPPED WITH A LOCKING REAR DIFFERENTIAL RPO G80. *NJ UPDATED 7/17/2008. *PE

  10. Manufacturer communication2000–2006 GMC YUKON ・ 2007-06-15

    New Design Front Axle Side Bearing Adjusters

    1. 1Fault

      Not stated

    2. 2Finding the cause

      Not stated

    3. 3Correction

      NEW DESIGN FRONT AXLE SIDE BEARING ADJUSTERS. *KB

    Read the sentences of the record
    Remedy
    NEW DESIGN FRONT AXLE SIDE BEARING ADJUSTERS. *KB

  11. Manufacturer communication2003–2006 GMC YUKON ・ 2006-01-25

    4WD Inoperative, Possible DTC C0327 in Transfer Case Control Module

    1. 1Fault

    2. 2Finding the cause

      Not stated

    3. 3Correction

      4WD INOPERATIVE AND POSSIBLE DTC C0327 STORED IN THE TRANSFER CASE CONTROL MODULE. *TT

    Read the sentences of the record
    Remedy
    4WD INOPERATIVE AND POSSIBLE DTC C0327 STORED IN THE TRANSFER CASE CONTROL MODULE. *TT

  12. Manufacturer communication2003–2006 GMC YUKON ・ 2005-11-09

    4WD Light and DTC C0374 Service Communication

    1. 1Fault

    2. 2Finding the cause

    3. 3Correction

    Read the sentences of the record
    Remedy
    SERVICE 4WD LIGHT ILLUMINATED, DIAGNOSTIC TROUBLE CODE (DTC) C0374 SET. *TT UPDATED 10/05/07. *NJ INSPECT WIRING HARNESS TO TRANSFER CASE SPEED SENSORS, REPLACE WIRING HARNESS. UPDATED 7/18/08 *PE

  13. Manufacturer communication2000–2006 GMC YUKON ・ 2005-11-02

    Electronic Transfer Case Unable to Complete Shift

    1. 1Fault

      Not stated

    2. 2Finding the cause

    3. 3Correction

      ELECTRONIC TRANSFER CASE UNABLE TO COMPLETE SHIFT. *TT

    Read the sentences of the record
    Remedy
    ELECTRONIC TRANSFER CASE UNABLE TO COMPLETE SHIFT. *TT

  14. Manufacturer communication2000–2005 GMC YUKON ・ 2005-09-22

    Intermittent 4WD Light with DTC C0306 or C0308 in TCCM

    1. 1Fault

    2. 2Finding the cause

      Not stated

    3. 3Correction

      INTERMITTENT SERVICE 4WD LIGHT COMES ON WITH DIAGNOSTIC TROUBLE CODE (DTC) C0306 OR C0308 STORED IN TCCM. *TT

    Read the sentences of the record
    Remedy
    INTERMITTENT SERVICE 4WD LIGHT COMES ON WITH DIAGNOSTIC TROUBLE CODE (DTC) C0306 OR C0308 STORED IN TCCM. *TT

  15. Manufacturer communication2000–2005 GMC YUKON ・ 2005-05-12

    Rear Axle Retainer Button Breakage Notification

    1. 1Fault

      Not stated

    2. 2Finding the cause

    3. 3Correction

      REAR AXLE RETAINER BUTTON BREAKAGE. *EH

    Read the sentences of the record
    Remedy
    REAR AXLE RETAINER BUTTON BREAKAGE. *EH

  16. Manufacturer communication2002–2005 GMC YUKON ・ 2005-05-11

    Intermittent MIL with DTC C0374 or Erratic 4WD/AWD Operation

    1. 1Fault

    2. 2Finding the cause

      Not stated

    3. 3Correction

      INTERMITTENT MALFUNCTION INDICATOR LAMP (MIL) WITH DIAGNOSTIC TROUBLE CODE (DTC) C0374 OR ERRATIC 4WD/AWD OPERATION. *TT

    Read the sentences of the record
    Remedy
    INTERMITTENT MALFUNCTION INDICATOR LAMP (MIL) WITH DIAGNOSTIC TROUBLE CODE (DTC) C0374 OR ERRATIC 4WD/AWD OPERATION. *TT

  17. Manufacturer communication2000–2005 GMC YUKON ・ 2005-04-21

    4WD Models with Noise, Vibration on Dry Pavement

    1. 1Fault

    2. 2Finding the cause

      Not stated

    3. 3Correction

      4WD MODELS WITH NOISE, VIBRATION ON DRY PAVEMENT. *EH

    Read the sentences of the record
    Remedy
    4WD MODELS WITH NOISE, VIBRATION ON DRY PAVEMENT. *EH

  18. Manufacturer communication2000–2005 GMC YUKON ・ 2005-04-20

    4L80E Output Carrier Thrust Washer Changes

    1. 1Fault

      Not stated

    2. 2Finding the cause

      Not stated

    3. 3Correction

      4L80E OUTPUT CARRIER THRUST WASHER CHANGES. *TT

    Read the sentences of the record
    Remedy
    4L80E OUTPUT CARRIER THRUST WASHER CHANGES. *TT

  19. Manufacturer communication2003 GMC YUKON ・ 2005-04-08

    SERVICE ENGINE SOON LIGHT AND NO-START CONDITION

    1. 1Fault

    2. 2Finding the cause

    3. 3Correction

      SERVICE ENGINE SOON LIGHT IS ILLUMINATED AND THE VEHICLE MAY NOT START. DIAGNOSTIC TROUBLE CODE P0706, WHICH RELATES TO TRANSMISSION RANGE SWITCH PERFORMANCE MAY BE STORED. *TT

    Read the sentences of the record
    Remedy
    SERVICE ENGINE SOON LIGHT IS ILLUMINATED AND THE VEHICLE MAY NOT START. DIAGNOSTIC TROUBLE CODE P0706, WHICH RELATES TO TRANSMISSION RANGE SWITCH PERFORMANCE MAY BE STORED. *TT

  20. Manufacturer communication2002–2003 GMC YUKON ・ 2005-03-07

    Fluid Leak from Front of Vehicle - Front Axle Vent Plug

    1. 1Fault

    2. 2Finding the cause

    3. 3Correction

      FLUID LEAK FROM FRONT OF VEHICLE ADD TEFLON TAPE TO FRONT AXLE VENT PLUG THREADS. *EH

    Read the sentences of the record
    Remedy
    FLUID LEAK FROM FRONT OF VEHICLE ADD TEFLON TAPE TO FRONT AXLE VENT PLUG THREADS. *EH

ENGINE AND ENGINE COOLING3

  1. Manufacturer communication2000–2006 GMC YUKON DENALI ・ 2024-02-02

    Piston Installation Procedure

    1. 1Fault

      Not stated

    2. 2Finding the cause

      Steps to confirm (in the document’s order)

      • Refer to the Engine Mechanical Specification in SI for the correct bore and piston specification.

    3. 3Correction

      Repair

      1. When installing a piston into a cylinder, use a ring compressor sleeve or equivalent for best results.
      2. Choose a sleeve with a smooth radius that tapers down to the specific bore size.
      3. Select a size only slightly bigger than the piston diameter and not larger than the cylinder bore diameter.

      Caution

      • If a sleeve is unavailable in the needed size, a universal ring compressor will work but is more difficult to use.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：Applies to 2024 and earlier GM passenger cars and trucks.
    • Repair：When installing a piston into a cylinder, use a ring compressor sleeve or equivalent for best results.
    • Repair：Choose a sleeve with a smooth radius that tapers down to the specific bore size.
    • Repair：Select a size only slightly bigger than the piston diameter and not larger than the cylinder bore diameter.
    • Confirm：Refer to the Engine Mechanical Specification in SI for the correct bore and piston specification.
    • Caution：If a sleeve is unavailable in the needed size, a universal ring compressor will work but is more difficult to use.

    Open the manufacturer’s document (PDF) ↗ The points above were read from this document.

    Remedy
    This PI bulletin advises the technician on the proper way to install the pistons in an engine.

  2. Manufacturer communication2000–2006 GMC YUKON DENALI ・ 2023-09-26

    Normal Transmission Shift and Throttle Response Delay

    1. 1Fault

      • A sag or hesitation may be noticed when coasting at low speeds of less than 24 km/h (15 mph) with a closed throttle and then aggressively applying the throttle.
      • With an automatic transmission, after a hard complete stop with a closed throttle immediately followed by an aggressive throttle opening, the downshifts may not be completed by the time the throttle is opened.
      • A sag or hesitation may also be noticed while cruising at highway speeds and then aggressively increasing the throttle, forcing a down-shift.

    2. 2Finding the cause

      Possible causes

      • In this maneuver the throttle blade is opened slowly for up to 0.7 seconds, even though the accelerator is applied aggressively, to help minimize driveline lash and clunking.
      • As a result, approximately 0.5 seconds of zero torque may be commanded to allow the shift to first gear to occur.

    3. 3Correction

      Caution

      • All of these conditions are a result of Torque Management and should be considered normal; no repairs should be attempted.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：GM passenger cars and trucks, model years 2000 to 2024.
    • Condition：A sag or hesitation may be noticed when coasting at low speeds of less than 24 km/h (15 mph) with a closed throttle and then aggressively applying the throttle.
    • Cause：In this maneuver the throttle blade is opened slowly for up to 0.7 seconds, even though the accelerator is applied aggressively, to help minimize driveline lash and clunking.
    • Condition：With an automatic transmission, after a hard complete stop with a closed throttle immediately followed by an aggressive throttle opening, the downshifts may not be completed by the time the throttle is opened.
    • Cause：As a result, approximately 0.5 seconds of zero torque may be commanded to allow the shift to first gear to occur.
    • Condition：A sag or hesitation may also be noticed while cruising at highway speeds and then aggressively increasing the throttle, forcing a down-shift.
    • Caution：All of these conditions are a result of Torque Management and should be considered normal; no repairs should be attempted.

    Open the manufacturer’s document (PDF) ↗ The points above were read from this document.

    Remedy
    The service bulletin advises the tech of a normal transmission shift condition and the delay in throttle response when the throttle plate is opened rapidly and advises the customer that it is normal for the delay.

  3. Manufacturer communication2003–2006 GMC YUKON DENALI ・ 2022-10-11(1 earlier editions of this document folded here)

    OEM and Remanufactured Engine/Transmission ID Notification

    1. 1Fault

      Not stated

    2. 2Finding the cause

      Steps to confirm (in the document’s order)

      1. The engine bar code tag could be on a rocker arm cover, on the ends of a cylinder head, or on the oil pan or oil rail area of the engine.
      2. All remanufactured engines have a label on the right or left side of the block.
      3. On the 4.8L/5.3L/6.0L/6.2L (Gen III/Gen IV) engines the remanufactured engine label is on the left side of the block.

    3. 3Correction

      Caution

      • If a piston must be replaced, measure the cylinder before ordering; most of these engines have oversized cylinders, and oversized piston ring packs are not available for service.
      • If crankshaft bearings must be replaced, measure the crankshaft before ordering; a crankshaft that has been turned must be replaced, together with all new standard size bearings.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：Applies to 2003–2023 GM passenger cars and trucks.
    • Confirm：The engine bar code tag could be on a rocker arm cover, on the ends of a cylinder head, or on the oil pan or oil rail area of the engine.
    • Confirm：All remanufactured engines have a label on the right or left side of the block.
    • Confirm：On the 4.8L/5.3L/6.0L/6.2L (Gen III/Gen IV) engines the remanufactured engine label is on the left side of the block.
    • Caution：If a piston must be replaced, measure the cylinder before ordering; most of these engines have oversized cylinders, and oversized piston ring packs are not available for service.
    • Caution：If crankshaft bearings must be replaced, measure the crankshaft before ordering; a crankshaft that has been turned must be replaced, together with all new standard size bearings.

    Open the manufacturer’s document (PDF) ↗ The points above were read from this document.

    Remedy
    This service bulletin provides information on OEM and Remanufactured Engine and Automatic Transmission/Transaxle Identification.

ELECTRICAL SYSTEM2

  1. Owner complaint2003 GMC YUKON ・ 2017-08-28

    Reduced engine power warning and deceleration while driving

    1. 1Fault

    2. 2Finding the cause

      Not stated

    3. 3Correction

      Not stated

    Read the sentences of the record
    Fault
    WHILE DRIVING APPROXIMATELY 50 MPH (= 80.5 km/h), THE VEHICLE EXPERIENCED INDEPENDENT DECELERATION AND THE REDUCED ENGINE POWER WARNING INDICATOR ILLUMINATED.
    Inspection
    THE VEHICLE WAS PREVIOUSLY TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE FUEL PUMP, SPARK PLUGS, TRANSMISSION, AND ALTERNATOR NEEDED TO BE REPLACED.
    Outcome
    THE VEHICLE WAS REPAIRED, BUT THE FAILURE RECURRED.

  2. Owner complaint2003 GMC YUKON DENALI ・ 2008-07-17

    Multiple electrical failures: turn signal activates hazard lights, inoperative gauges, battery failure, and gear shift noise

    1. 1Fault

    2. 2Finding the cause

    3. 3Correction

    Read the sentences of the record
    Fault
    THE CONTACT STATED THAT EVERYTIME HE ACTIVATED HIS LEFT TURN SIGNAL, THE HAZARD WARNING LIGHTS WOULD ILLUMINATE. (3 more)
    Remedy
    HE TOOK THE VEHICLE TO THE DEALER ON NUMEROUS OCCASIONS AND A TECHNICIAN REPLACED THE BATTERY AND ALTERNATOR TWICE, AND THE ENTIRE INSTRUMENT CONTROL PANEL AS WELL.

ENGINE2

  1. Manufacturer communication2003–2006 GMC YUKON DENALI ・ 2021-04-20

    Engine and Transmission Identification

    1. 1Fault

      Not stated

    2. 2Finding the cause

      Not stated

    3. 3Correction

      OEM and Remanufactured Engine and Automatic Transmission/Transaxle Identification

    Read the sentences of the record
    Remedy
    OEM and Remanufactured Engine and Automatic Transmission/Transaxle Identification

  2. Manufacturer communication2003–2006 GMC YUKON DENALI ・ 2018-05-21

    Revision to 01-00-89-010I Adding 2013 Model Year

    1. 1Fault

      • The bulletin is a reference and strategy document for reducing customer comebacks and buyback situations.

    2. 2Finding the cause

      Not stated

    3. 3Correction

      This informational bulletin provides a revision for 01-00-89-010I to add the 2013 model year.

    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：Applies to 2013 and prior GM passenger cars and trucks.
    • Condition：The bulletin is a reference and strategy document for reducing customer comebacks and buyback situations.

    Open the manufacturer’s document (PDF) ↗ The points above were read from this document.

    Remedy
    This informational bulletin provides a revision for 01-00-89-010I to add the 2013 model year.

ELECTRONIC STABILITY CONTROL1

  1. Owner complaint2003 GMC YUKON ・ 2006-11-10

    Traction Active indicator illuminates during acceleration, powertrain disengages

    1. 1Fault

    2. 2Finding the cause

      Not stated

    3. 3Correction

      Not stated

    Read the sentences of the record
    Fault
    40,000 MI.: WHEN ACCELERATING FROM A STOP, THE "TRACTION ACTIVE" DASH DISPLAY WILL VERY OFTEN COME ON, THE POWERTRAIN DISENGAGES AND I HAVE TO LET UP ON GAS UNTIL TRANSMISSION RE-ENGAGES. (1 more)
    Inspection
    A GM DEALER, AFTER EXAM & DIAGNOSTICS, COULD FIND NO PROBLEM, EVEN AFTER BEING ADVISED ABOUT POSSIBLE "WHEEL CORROSION."
    Consequence
    I HAVE ALMOST BEEN REAR-ENDED, SINCE THE DRIVERS BEHIND ME PRESUPPOSE I WILL CONTINUE ACCELERATING.

EQUIPMENT1

  1. Manufacturer communication2003–2006 GMC YUKON DENALI ・ 2018-06-04(1 earlier editions of this document folded here)

    Automatic Transmission Oil Cooler Flow Test Essential Tool J-45096

    1. 1Fault

      • In flow mode, an electronic flow meter measures the flow capability of the ATF oil cooling system.

    2. 2Finding the cause

      Steps to confirm (in the document’s order)

      1. On the 4L60-E, the cooler feed (exiting the transmission) is the bottom connector and the return (entering the transmission) is the top connector; J-35944-200 may be required.
      2. On the 4L80-E, the cooler feed is the front connector and the return is the rear connector; J-35944-200 may be required.

    3. 3Correction

      Repair

      • For the flow test and flush procedure, refer to Automatic Transmission Oil Cooler Flushing and Flow Test J-45096 in SI.

      Caution

      • Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure; the required minimum flow rate depends directly on the supply oil temperature.
      • The oil in the supply vessel must be 18°C (65°F) or warmer for the J-45096 to operate.
      • Labor operations that remove the transmission for an internal repair or torque converter replacement include time to flow check and flush the transmission oil cooler system.
      • A flow test and flush uses between 4.7-7.5 L (5-8 qts) of DEXRON VI transmission fluid.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：Applies to 2011 and prior GM passenger cars and light duty trucks with an automatic transmission/transaxle.
    • Condition：In flow mode, an electronic flow meter measures the flow capability of the ATF oil cooling system.
    • Caution：Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure; the required minimum flow rate depends directly on the supply oil temperature.
    • Caution：The oil in the supply vessel must be 18°C (65°F) or warmer for the J-45096 to operate.
    • Confirm：On the 4L60-E, the cooler feed (exiting the transmission) is the bottom connector and the return (entering the transmission) is the top connector; J-35944-200 may be required.
    • Confirm：On the 4L80-E, the cooler feed is the front connector and the return is the rear connector; J-35944-200 may be required.
    • Repair：For the flow test and flush procedure, refer to Automatic Transmission Oil Cooler Flushing and Flow Test J-45096 in SI.
    • Caution：Labor operations that remove the transmission for an internal repair or torque converter replacement include time to flow check and flush the transmission oil cooler system.
    • Caution：A flow test and flush uses between 4.7-7.5 L (5-8 qts) of DEXRON VI transmission fluid.

    Open the manufacturer’s document (PDF) ↗ The points above were read from this document.

    Remedy
    This informational bulletin provides information for Automatic Transmission Oil Cooler Flow Test Essential Tool J-45096 TransFlow.

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