Five problems related to frame and members have been reported for the 2002 Chevrolet Avalanche. The most recently reported issues are listed below.
The rear window frame is breaking off of the glass. The frame and/or glass could become a projectile in the event of a crash. These stress fractures in the window frame occurred with the window in the installed position and I first noticed them on Sunday March 21, 2004. I have only removed the window once and that was over a year ago. The vehicle has never been in an accident and had approximately 45,000 miles on it when I noticed the fractures. This is an obvious manufacturer defect however when I took the vehicle to the dealership I was told that this was not covered under the warranty. I contacted gm customer service and was basically told the same thing. I believe that this defect is serious enough to warrant a recall.
While traveling on a state 2 lane highway at high way speed, the spare tire dropped from it's storage area under truck bed. Cable system holding spare in place had frayed and worn through to breaking point, thus releasing inflated spare onto road surface, causing spare to bounce approximately 6 feet into air and rolled off the high way on to shoulder at speed.
Rear 3 panel deck lid leaks. 2 dealers stated that the deck lid is not advertised as "waterproof", only "weatherproof". The deck lid leaks when parked or driving thru light rain.
Consumer states that when it rains water is coming from the mid gate off the vehicle and weting up the inside, as a result of the way it is design. Had vehicle serviced 8-9 times for the same problem. Dealership unable to fix problem ts.
Per consumer" at time of assembly of vehicle's frame there was a failure that caused the metal to flex and break after a period of time. If the dealership corrects the problem it will make the frame weaker".