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2002 Chevrolet Cavalier Recalls, Problems & Maintenance

The 2002 Chevrolet Cavalier has no open NHTSA recalls. Owners report 8 recurring issue clusters, led by “Brake rotor warping and brake shudder.” Chevrolet vehicles use the GM Oil Life System (OLS) — a percentage-based monitor that calculates oil life from driving conditions, not fixed mileage. When the OLS drops to 0%, oil and filter are due. The schedule below reflects GM's Normal Use intervals for everything else.

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No open recalls on file. NHTSA lists no unrepaired safety recalls for this year, make and model. A recall can be issued at any time, and a specific car can still have one open — check yours by VIN at nhtsa.gov/recalls.

Known issues & problems for this vehicle

What drivers and federal regulators have officially reported about the 2002 Chevrolet Cavalier.

Reported to NHTSA

Brake rotor warping and brake shudder

SERVICE BRAKES, HYDRAULIC

6 NHTSA complaints · 2003-03 → 2006-07

“AT 13,000 MILES MY CAR WOULD SHAKE VIOLENTLY WHEN APPLYING THE BRAKES. THE DEALER SAID THE ROTORS WERE WARPED, THE DEALER TURNED THEM AND THE SHAKING STOPPED”
— Owner report, NHTSA ODI #10010384
“THE BRAKE ROTORS HAD TO BE REPLACED FIVE TIMES IN THE LAST THREE YEARS DUE TO DEFECT”
— Owner report, NHTSA ODI #10115106
“AT APPROXIMATELY 30000 MILES MY CAR WOULD SHAKE OR BOUNCE, SOMETIMES VIOLENTLY, WHEN THE BRAKES WERE APPLIED. THE BRAKE PADS AND ROTORS WERE CHECKED AND IT WAS DETERMINED THAT THE ROTORS WERE WARPED, THOUGH THE PADS WERE OK”
— Owner report, NHTSA ODI #10161943

Read all complaints on NHTSA →

Timing chain, tensioner and gear failure

ENGINE AND ENGINE COOLING

4 NHTSA complaints · 2004-12 → 2011-03

“TIMING CHAIN BROKE AT ABOUT 45 MPH, CAUSING ENGINE TO FAIL. RESULTS DETERMINED BY THE DEALER SHOWED THAT TIMING CHAIN SHATTERED, TEARING UP THE ENGINE”
— Owner report, NHTSA ODI #10103359
“TIMING CHAIN BROKE ON 2002 CHEVROLET CAVALIER LS CAUSING CATASTROPHIC ENGINE FAILURE. AUTOMOBILE ONLY HAS 70,000 MILES ON A WELL MAINTAINED MOTOR”
— Owner report, NHTSA ODI #10393539
“DT: 2002 CHEVROLET CAVALIER. THE CONSUMER STATED THERE WAS A CONSTANT PROBLEM WITH THE TIMING CHAIN GEAR, TENSIONER, AND CHAIN ITSELF. IT WAS REPLACED ON FEBRUARY 22, 2005, AND NEEDED TO REPLACED AGAIN”
— Owner report, NHTSA ODI #10136936

Read all complaints on NHTSA →

Power window motor and regulator failure

VISIBILITY

10 NHTSA complaints · 2003-09 → 2008-03

“HAVE HAD TO REPLACE POWER WINDOW MOTORS A TOTAL OF 5 TIMES. LESS THAN 80,000 MILES. ONE DRIVER. NO ABUSE”
— Owner report, NHTSA ODI #10167519
“THE WINDOW MOTORS HAVE BURNED OUT ON BOTH OF MY AUTOMATIC WINDOWS AT A LOW MILEAGE. THE PASSENGER SIDE MOTOR HAD TO BE REPLACED AT 35,000 MILES AND NOW THE DRIVER'S SIDE MUST BE REPLACED AT 60,000”
— Owner report, NHTSA ODI #10221746
“POWER WINDOWS FAIL-THIS IS THE SECOND TIME WITH ONE YEAR THAT THE POWER WINDOW HAS FAILED, ORIGINALLY THE LEFT DRIVER'S SIDE WINDOW FAILED, HAD THE MOTOR REPLACED, NOW THE RIGHT FRONT PASSENGER HAS FAILED AND AT TIMES THE LEFT DRIVER'S WINDOW STOPS WORKING”
— Owner report, NHTSA ODI #10036990

Read all complaints on NHTSA →

Fuel pump failure and engine stalling

FUEL SYSTEM, GASOLINE

7 NHTSA complaints · 2007-11 → 2014-11

“THE ENGINE QUITS RUNNING WHILE DRIVING AT HIGHWAY SPEEDS WITHOUT ANY WARNING. AFTER PULLING OFF TO THE SIDE OF THE ROAD,THE ENGINE MAY RESTART IMMEDIATELY OR AFTER A FEW MINUTES. A TECHNICIAN DIAGNOSED THIS AS A FAULTY FUEL PUMP”
— Owner report, NHTSA ODI #10329719
“2002 CHEVROLET CAVALIER STALLED WITHOUT WARNING. CONSUMER STATES THAT THE VEHICLE WAS NOT ABLE TO BE RESTARTED AND WAS TOWED TO A DEALER. THE DEALER STATED THAT THE FUEL PUMP HAD GONE OUT”
— Owner report, NHTSA ODI #10216109
“WHOLE VEHICLE FILLED WITH GAS FUMES. CHECK GAUGES LIGHT WENT ON AND FUEL GAUGE FAILED IN IDLE. REPLACED FUEL PUMP AT DEALERSHIP AT A COST OF 770.72”
— Owner report, NHTSA ODI #10209385

Read all complaints on NHTSA →

Traction system warning light with engine shutdown

ELECTRICAL SYSTEM

11 NHTSA complaints · 2003-11 → 2010-09

“THE TRACTION OFF WARNING LIGHT ILLUMINATED WHICH CAUSED THE VEHICLE TO SHUT DOWN. THE VEHICLE WAS TAKEN TO THE DEALER WHO REPLACED THE FUEL PUMP AND FUEL INJECTION SYSTEM BUT THE REPAIRS MADE DID NOT CORRECT THE PROBLEM WITH THE ENHANCED TRACTION SYSTEM”
— Owner report, NHTSA ODI #10105555
“THERE WERE ENHANCED TRACTION SYSTEM PROBLEMS WHICH WERE CONTINUOUS. THE FUEL PUMP WAS REPLACED AND DID NOT RESOLVE THE PROBLEM WITH THE ETS”
— Owner report, NHTSA ODI #10103589
“TRAC OFF WARNING LIGHT ETS (ELECTRONIC TRACTION SYSTEM) CAME ON. REPAIRS DID NOT CORRECT THE PROBLEM WITH THE ETS”
— Owner report, NHTSA ODI #10107112

Read all complaints on NHTSA →

Rear turn signal and brake light failure

EXTERIOR LIGHTING

10 NHTSA complaints · 2003-09 → 2020-07

“2002 CAVALIER- REAR RIGHT TURN SIGNAL AND STOP LIGHT BECOME INACTIVE- I THOUGHT THAT THE BULB BURNED OUT. WHEN I REPLACED THE BULB, IT STOPPED WORKING AGAIN AFTER A WHILE”
— Owner report, NHTSA ODI #10192077
“DT*: THE CONTACT STATED THE TAIL LIGHTS AND TURN SIGNALS WERE OBSERVED TO BE INOPERABLE. THE VEHICLE WAS DRIVEN TO THE DEALER WHO DETERMINED THE TAIL LIGHT CIRCUIT BOARD NEEDED TO BE REPLACED”
— Owner report, NHTSA ODI #10173040
“THE BLINKER ASSEMBLY UNIT IS BURNING OUT THE BULB ON THE REAR PASSENGER SIDE EVERY OTHER DAY”
— Owner report, NHTSA ODI #10111076

Read all complaints on NHTSA →

Air bags not deploying in collision

AIR BAGS

5 NHTSA complaints · 2002-09 → 2007-01

“I WAS INVOLVED IN A MAJOR ACCIDENT WHICH RESULTED IN THE TOTALING OF MY 2002 CHEVROLET CAVALIER. ALTHOUGH THERE WAS CONSIDERABLE FRONT-END DAMAGE THE AIRBAGS DID NOT DEPLOY”
— Owner report, NHTSA ODI #10179317
“WAS DRIVING A 2002 CHEVROLET CAVALIER LS SPORT AT 40 MPH. WHEN ANOTHER VEHICLE PULLED OUT IN FRONT OF ME,I ENDED UP T-BONING THE 2ND VEHICLE AT 40MPH NO TIME TO HIT BRAKES, ALL FONTAL DAMAGE AND AIR BAGS NEVER DEPLOYED”
— Owner report, NHTSA ODI #10051482
“VEHICLE WAS IN A FRONTAL COLLISION, BUT NONE OF THE AIR DEPLOYED UPON IMPACT”
— Owner report, NHTSA ODI #10006774

Read all complaints on NHTSA →

Unintended acceleration and cruise control non-release

VEHICLE SPEED CONTROL

9 NHTSA complaints · 2002-11 → 2010-12

“WHILE DRIVING 60 MPH, WITHOUT WARNING THE VEHICLE SUDDENLY ACCELERATED. THE DRIVER WAS ABLE TO MAINTAIN CONTROL OF THE VEHICLE AND TOOK IT TO THE DEALER FOR INSPECTION. THE MECHANIC WAS UNABLE TO DUPLICATE THE PROBLEM”
— Owner report, NHTSA ODI #10073411
“CRUISE CONTROL STAYED ON AFTER HITTING BREAKS EVEN TRIED SWTICHING IT OFF AND THAT DID NOT WORK ONLY WHEN I PRESSED IN ON THE CLUTCH DID IT DISENGAGE”
— Owner report, NHTSA ODI #10172514
“WHEN VEHICLE IS IN GEAR WITH FOOT ON THE BRAKES ENGINE WILL START RACING, AND VEHICLE WILL ACCELERATE ON ITS OWN”
— Owner report, NHTSA ODI #10058037

Read all complaints on NHTSA →

Issues on other model years

Source: NHTSA Office of Defects Investigation (ODI). Complaint data refreshed Sep 20, 2026. Investigation data refreshed Sep 20, 2026.

We display NHTSA's record with attribution; we don't editorialize on what these complaints mean for any specific vehicle.

Raw data + downloads for this vehicle →

Essential maintenance

Critical for safety and preventing major damage

Engine Oil & Filter (per Oil Life System)

Every 7,500 mi

Change oil when the Oil Life System reaches 0% or every 12 months — whichever comes first. dexos1-approved synthetic oil required on all gas engines since 2011.

Estimated cost — typical U.S. ranges

Dealer

~$120–$160

Shop

~$85–$115

DIY

~$25–$55

Full synthetic costs more than conventional. 5-quart 0W-20 + filter is the typical bill.

Tire Rotation

Every 7,500 mi

Rotate tires every 7,500 miles. Silverado 4x4 and Tahoe owners benefit from earlier rotations to even out drivetrain wear.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Often free at the shop where you bought the tires — worth asking before paying.

Brake Inspection

Every 7,500 mi

Inspect brake pads, rotors, and parking brake at each tire rotation. Equinox and Malibu front pads typically last 40,000-50,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Most shops do this free as a courtesy with any service. Don't pay separately if you can avoid it.

Brake Fluid

Every 45,000 mi

GM specifies brake fluid replacement based on contamination testing. Test every 30,000 miles; replace if moisture content exceeds 3% or fluid appears dark.

Estimated cost — typical U.S. ranges

Dealer

~$180–$200

Shop

~$125–$140

DIY

~$10–$25

DOT 3 or 4 — match the cap. Vacuum bleeders make this a one-person DIY.

Important maintenance

Keeps your vehicle running smoothly and efficiently

Engine Air Filter

Every 45,000 mi

GM long-life cellulose air filters are rated 45,000 miles. Direct-injection engines are sensitive to airflow restriction; inspect at every oil change.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

5-minute job on most cars; the airbox lid usually has clips, no tools needed.

Automatic Transmission Fluid

Every 45,000 mi

Severe service (heavy towing, frequent stop-and-go, dusty conditions): replace every 45,000 miles. Normal service: 97,500 miles. Use Dexron-VI on 6L80/8L90 transmissions.

Estimated cost — typical U.S. ranges

Dealer

~$330–$500

Shop

~$235–$355

DIY

~$60–$180

Some sealed transmissions have no dipstick — fill is precise and best left to a shop. Many drivers can still DIY drain-and-fill.

Transfer Case Fluid (4WD)

Every 45,000 mi

On 4WD models, replace transfer case fluid every 45,000 miles — sooner if towing or off-roading. Use GM Auto-Trak II fluid.

Estimated cost — typical U.S. ranges

Dealer

~$105–$140

Shop

~$75–$100

DIY

~$15–$40

AWD/4WD vehicles only. Easy drain-and-fill on most platforms.

Spark Plugs

Every 100,000 mi

GM iridium spark plugs are rated 100,000 miles on most LS and LT engines. The 5.3L V8 in Silverado 1500 commonly fouls plugs early under heavy idling.

Estimated cost — typical U.S. ranges

Dealer

~$285–$390

Shop

~$200–$275

DIY

~$25–$100

Iridium plugs cost more but last 100k+ miles. V6/V8 access varies wildly — some are tough.

Dex-Cool Engine Coolant

Every 50,000 mi

GM Dex-Cool (orange): first change at 150,000 miles or 5 years, then every 50,000 miles. Mixing with green coolant creates a sludge that destroys the cooling system.

Estimated cost — typical U.S. ranges

Dealer

~$285–$330

Shop

~$200–$235

DIY

~$25–$60

Use the manufacturer-specified coolant — wrong color/chemistry can damage the cooling system.

Rear Differential Fluid

Every 50,000 mi

Silverado and Tahoe: replace rear axle fluid every 50,000 miles, or 25,000 miles if towing. Limited-slip differentials require GM friction-modifier additive.

Estimated cost — typical U.S. ranges

Dealer

~$150–$195

Shop

~$105–$135

DIY

~$20–$50

Drain plug + fill plug — straightforward DIY. AWD vehicles have two; budget for both.

Recommended maintenance

Extends the life of your vehicle and improves comfort

Cabin Air Filter

Every 22,500 mi

Replace the cabin air filter every 22,500 miles. Silverado and Tahoe owners in dusty climates should replace earlier.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

Usually behind the glovebox. Shops charge labor for a 10-minute job — easy DIY win.

Fatal crash history & reported problems

Occupant deaths in fatal crashes (FARS)

788 crashes 1990–2024

How the 788 occupant deaths break down

565

driver deaths

223

passenger deaths

788

occupant deaths

Crash years covered: 1990–2024 This model year first appears in 2001 crashes. Older models have had more years on the road to appear in these crashes, so a higher count here does not by itself mean a vehicle is less safe.

FARS counts every occupant death in a fatal crash, whatever the cause — it does not mean the vehicle was at fault or defective. Counts are not adjusted for how many of each vehicle are on the road. How to read this number

FARS 2024 data is an annual report file. NHTSA revises these records when the final file is published, so this count can change.

Why we show driver deaths too

Every vehicle has exactly one driver seat, so driver deaths line up fairly when you compare one model to another. Occupant deaths include passengers, so a three row SUV can show a higher number than a two seat car simply because it carries more people.

Both figures are plain counts, not rates. A rate would need to know how many of each vehicle are on the road, and that registration data is not public, so we do not publish rates or scores of any kind.

IIHS publishes driver death rates using this same driver only idea, paired with a registered vehicle years denominator we do not have. Their rates and these counts answer different questions, so do not read either number here as a safety rating.

Owner-reported problem signals

Separate from the federal fatality data above: complaints owners filed with NHTSA about this year and model. These are reports of problems, unverified, and are counted here only as signals.

26

complaints mentioning a crash

4

complaints mentioning a fire

Reviewed known issues for this vehicle

Typical U.S. ranges. Actual quotes vary by shop, parts choice, and vehicle condition.

How we estimate: Dealer = OEM parts × 1.4 + labor × $165/hr. Shop = parts + labor × $115/hr. DIY = parts only.

This maintenance schedule for the 2002 Chevrolet Cavalier reflects Chevrolet's published service intervals and the Oil Life System system. Your actual service needs may vary based on driving conditions, climate, and vehicle usage. Always consult your owner's manual for model-specific recommendations.

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