Oxygen sensor tends to fail regularly,I have replaced it 3 times in the last 4 years.
Rear Dutch doors are very stiff, challenging to close.
Sliding door bearings have seized requiring repacing.
Fuel rail starting leaking and the engines started to back fire because of too much fuel in the injectors.
We are the second owners and for the repairs we have had to do, we consider them minor for the effort put out.
One concern we do have is that it uses a lot of gas.
However for the strength and performance, its worth it. It is a great highway vehicle.
The fuel rail is a problem with the Vortex engines. They suseptable to springing a leak and cannot be repaired. You have to buy a new one and at a cost of $700.00,GMC should be sending out a re-call notice. I had to replace this part.
There have been some electrical issues starting to develop. Door locks and windows are starting to fail. The wires are starting to crack and split, causing the power windows and door locks to work intermitantly.
The front seats are very uncomfortable, especially the passengers seat, no leg room.
However, good room for the rear seats for a 8 passenger van.
I had my '92 Safari AWD/ext with a vortec engine for 3 yrs. the 1st year there wasn't too much aside from general maintenance.
Year 2. was a totally different story!
I had to replace the following:
water pump, torsion bar, exhaust system, shocks, front drive shaft, lower ball joints, upper ball joint, idler arms both sides 2x., radiator, 3 alignments and 2 sets of tires. brakes seized and burned up $600 (while up north had to get it towed to the shop).
Year 3. replaced water pump again, A/C is gone, power windows are only working intermittently, replaced shocks all around $240, replaced brake cylinder $200, had to take out the front drive shaft and in process of trying to find one at the wreckers, dealer quotes $900 for the front drive shaft (new). alignment again, and another full set of tires.
Had to replace the injector coil (from wreckers $300). O2 sensor $130, water pump 100, idler arms again at $240 each and $150 labour.
Had to fix the manifold gasket $250, replace tranny lines $100 replace fuel lines $175. both rear A/C and heater had to be disconnected. My mechanic told me that brake rotor may be warped. Rear door lock never worked have to use power door locks to un/lock and it has always been very hard to open. Now when I start it there is a grinding sound.
This van is also a pig on gas compared to my last two vans (ford aerostars) I get about 550/tank (128 liter fuel tank)
and has given me more problems than they have. However, it is a solid truck, but the steering is sloppy compared to all my other past vehicles (I normally replace my vehicles every 2 yrs). For long distance driving the drivers side and passenger side leave a lot to be desired.
I have total confidence that the engine and tranny will last another 200,000 kilometers (currently at 312,000 kms.
Would I buy another GM product? Yes. Another Safari AWD or GMC 4x4/AWD?... Never!