Summary
The GMC G Series has 24 recalls spanning 1976 through 2003, with the most serious recent issue being a 2003 model year running board courtesy light that can overheat when moisture and road salt reach the wiring harness, melting the running board or starting a fire. This applies only to vehicles fitted with Southern Comfort running boards containing American Technology Components lights.
The 1997 model year has a brake pipe routing problem where the lower engine oil cooler hose rubs against the front left brake pipe over time, wearing a hole through it and reducing front braking performance. On 1996 models, water can leak into the kick panel area and reach electrical components there. The 1995 sliding side door latch can be improperly riveted and fail to hold in a crash. On 1993 G2 models, an incorrect spare wheel originally specified for a smaller van can crack and separate from the vehicle under load, causing loss of control without warning.
The early 1990s have several issues. The 1992 model has a lower control arm that can crack near the ball joint pad and eventually allow the ball joint to separate from the arm, causing sudden loss of steering. A separate 1992 issue involves a master cylinder that does not meet hydraulic brake system requirements and can fail during a partial brake system failure. A 1992 transmission compliance recall involves the vehicle being startable while in gear. The 1990 model has tie rod clamp fasteners that can loosen and allow the tie rod to separate, leading to loss of steering control if the affected wheel encounters a bump or heavy braking.
Going further back, the 1989 rear bench seat back frame can yield under load, and the 1988 seat pedestal anchors can fail to hold under required loads. The 1987 model year has a fuel fill pipe with faulty welds that can leak fuel during filling or sloshing, and a service replacement sliding door latch that may not hold in a crash. The 1985 lower control arm can crack near the rear flange and progress to the ball joint mounting hole, causing ball joint separation and loss of control. The 1984 model, if propane-fueled, has a missing crimp on the shutoff valve housing that allows the valve stem to be turned out too far and leak propane. On 1978 models with the 292 cubic inch engine and air conditioning, the carburetor fuel line can wear through where it contacts the air conditioner bracket, risking an engine compartment fire. That same year, swivel bucket seat attachment nuts can loosen during normal use, allowing the seat to break free unexpectedly. The 1977 model has a right front brake pipe that can rub against the steering relay rod and eventually wear through, causing loss of front braking. The 1976 G3 and P30 model year has brake master cylinder reservoir mounting bolts that can break, leading to partial or complete hydraulic brake failure.