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Chevrolet · Known Issues

1999 Chevrolet C/K 2500 Problems: 4 Known Issues

1999 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated September 2026

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Issue summary

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1999 Chevrolet C/K 2500 has 4 documented known issues, with 2 rated critical. The most serious are 6.5L Diesel Injection Pump (PMD/FSD) Failure ($300-$2,500 repair) and Brake Line Corrosion and Rust-Through ($400-$1,500 repair). Across all issues with published estimates, repair costs range from $300 to $2,500. DIY maintenance guides at au7o.io.

In This Article

  • C/K 2500 Engine1
  • C/K 2500 Brakes1
  • C/K 2500 Drivetrain1
  • C/K 2500 Fuel System1
  • FAQ
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In This Article

  • Engine1
  • Brakes1
  • Drivetrain1
  • Fuel System1
  • FAQ

All 4 Known Issues

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ALL YEARS20032002200120001999199819971996199519941993199219911990

On the 1994-2000 Chevrolet C/K 2500 6.5L Diesel, the 6.5L diesel uses a Stanadyne DB2 injection pump with a Pump Mounted Driver (PMD/FSD) electronic module that overheats and fails, causing stalling and no-start conditions. This is the most common failure on 6.5L diesel trucks.

This issue also affects: GMC C/K 2500

Common Symptoms

  • Stalling while driving
  • No start when hot
  • Hard starting
  • Loss of power

How to Fix

Confirm PMD/FSD failure by checking for stall/no-start when hot, verifying power/ground at the injection pump, and scanning for related OBD-I/OBD-II diesel fault codes; a known-good remote-mounted PMD test module is often the quickest confirmation. Replace the failed PMD/FSD with a quality updated module and calibration resistor, then relocate it from the pump to a heat-sink mounted in a cooler area (commonly behind the bumper or grille) using an extension harness to prevent repeat overheating. Inspect and clean injection pump connectors, grounds, and the engine harness during the repair, because poor connections can mimic PMD failure. Parts typically run about $150-$350 for a PMD kit with heat sink and harness, while complete repair cost is usually $250-$600 depending on labor and whether additional wiring repairs are needed.

Typical repair cost:$300 - $2,500

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Community Reported
Medium Confidence

On the 1999-2003 Chevrolet C/K 2500, brake lines on C/K 2500 trucks (and all GMT800 full-size GM trucks from 1999-2003) corrode and rust through, particularly in northern states where road salt is used. NHTSA investigated approximately 6 million vehicles but GM did not issue a recall, calling it a maintenance issue. Brake lines run along the frame rail and corrode under securing clips where moisture is trapped.

Common Symptoms

  • Soft or spongy brake pedal
  • Brake fluid leaking under vehicle
  • Low brake fluid warning light
  • Visible rust and flaking on brake lines
  • Brake pedal goes to floor

How to Fix

Typical repair cost:$400 - $1,500

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Community Reported
Medium Confidence

On the 1996-2000 Chevrolet C/K 2500, the NP241 and NP246 transfer cases used in 4WD C/K 2500 trucks develop chain stretch over time, typically after 160,000-200,000 miles. The stretched chain causes popping noises under load, delayed 4WD engagement, and eventual 4WD failure. The NP246 Auto-Trac version is more problematic due to its encoder motor and clutch pack design.

Common Symptoms

  • Loud popping noise in 4WD under load
  • Grinding or clicking sound from transfer case
  • Delayed engagement when shifting into 4WD
  • Service 4WD light illuminated
  • Clunking when accelerating from stop in 4WD

How to Fix

Typical repair cost:$400 - $1,500

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On the 1990-2000 Chevrolet C/K 2500, same fuel pump failure issue as the C/K 1500. The dual-tank equipped models have an additional failure point with the tank selector valve which can cause fuel starvation.

This issue also affects: Chevrolet Blazer, Chevrolet Express, Chevrolet S-10

Common Symptoms

  • Engine stalling
  • Hard starting
  • Loss of power
  • Fuel gauge inaccuracy

How to Fix

Confirm the fault by checking fuel pressure at the TBI or CPI rail and verifying pump power/ground at the tank connector; low or unstable pressure, especially under load, usually indicates a failing in-tank pump or restricted strainer. Replace the in-tank fuel pump module, sock/strainer, and fuel filter, and inspect the tank wiring connector for heat damage; on dual-tank trucks, also test the tank selector valve for proper switching and fuel flow because a failed valve can mimic pump failure and cause starvation. If one tank reads incorrectly or the gauge is erratic, inspect the sending unit while the tank is down and replace it if worn. Typical repair cost is about $350-$900 for a single pump job, or $500-$1,200+ on dual-tank models if the selector valve or both sending units need service.

Typical repair cost:$400 - $900

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Frequently Asked Questions

What are the most common Chevrolet C/K 2500 problems?

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1999 Chevrolet C/K 2500 has 4 documented issues. The most frequently reported are: 6.5L Diesel Injection Pump (PMD/FSD) Failure, Brake Line Corrosion and Rust-Through, NP241/NP246 Transfer Case Chain Stretch. Of these, 2 are rated critical and should be addressed promptly.

Is the Chevrolet C/K 2500 reliable?

The 1999 Chevrolet C/K 2500 has 4 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 2 issues are rated critical: 6.5L Diesel Injection Pump (PMD/FSD) Failure and Brake Line Corrosion and Rust-Through. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Chevrolet C/K 2500 problems?

Repair costs for known Chevrolet C/K 2500 issues range from $300 to $2,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, 6.5L Diesel Injection Pump (PMD/FSD) Failure, typically costs $300-$2,500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 1994-2000 Chevrolet C/K 2500 6.5L Diesel Injection Pump (PMD/FSD) Failure?

The 6.5L diesel uses a Stanadyne DB2 injection pump with a Pump Mounted Driver (PMD/FSD) electronic module that overheats and fails, causing stalling and no-start conditions. This is the most common failure on 6.5L diesel trucks. Repairs typically run $300-$2,500. Severity: high.

What is the 1999-2003 Chevrolet C/K 2500 Brake Line Corrosion and Rust-Through?

Brake lines on C/K 2500 trucks (and all GMT800 full-size GM trucks from 1999-2003) corrode and rust through, particularly in northern states where road salt is used. NHTSA investigated approximately 6 million vehicles but GM did not issue a recall, calling it a maintenance issue. Repairs typically run $400-$1,500. Severity: high.

Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.

Data compiled from NHTSA recalls, manufacturer TSBs, automotive forums, and AI-assisted research. No aggregated owner-report counts available for this vehicle yet.

What is the 1996-2000 Chevrolet C/K 2500 NP241/NP246 Transfer Case Chain Stretch?

The NP241 and NP246 transfer cases used in 4WD C/K 2500 trucks develop chain stretch over time, typically after 160,000-200,000 miles. The stretched chain causes popping noises under load, delayed 4WD engagement, and eventual 4WD failure. The NP246 Auto-Trac version is more probl… Repairs typically run $400-$1,500. Severity: medium.

What is the 1990-2000 Chevrolet C/K 2500 In-Tank Fuel Pump Failure?

Same fuel pump failure issue as the C/K 1500. The dual-tank equipped models have an additional failure point with the tank selector valve which can cause fuel starvation. Repairs typically run $400-$900. Severity: medium.