143 of the
1,453 complaints filed about the Chevrolet Silverado 3500
are about the fuel system —
10% of everything owners reported.
The worst model year for it is 2015.
I own a 2015 Chevrolet Silverado 3500HD Duramax diesel. At approximately 130,000 miles, the high-pressure CP4 fuel pump failed internally, sending metal shavings throughout the fuel system and contaminating major components. The truck suddenly lost power on the freeway and became inoperable without warning. I was barely able to get out of traffic before it had to be towed to a Chevrolet dealership. This created a serious safety hazard, especially considering the risk if it had happened while towing my fifth wheel with my family. A failure like this should not happen at this mileage on a heavy-duty diesel truck. I also cannot afford the extremely high cost of repairing the entire fuel system. From my research, many other owners have experienced the same CP4 fuel pump failure, which often destroys the entire fuel system and leads to very expensive repairs. I believe this is a widespread defect, not normal wear and tear. I ask NHTSA to review these failures and take action to protect vehicle owners from similar dangerous and costly failures. This truck currently sits at the dealership as I cannot afford the repairs and GM will not fix what they know is faulty parts.
NHTSA complaint #11751378 — an unverified report by a vehicle owner.
Truck was operating on the highway at highway speed. Suddenly the truck went into a drastic engine power reduction mode and severe automatic downshifting occurred; the truck came to a complete stop on the highway. Diagnostics proved to be a CP4 injector pump failure sending metal into the fuel system, needing a complete contamination kit and new CP3 pump conversion. This apparently is a known defect in GM vehicles and should have been recalled.
NHTSA complaint #11751129 — an unverified report by a vehicle owner.
The fuel pump driver module. I filled my truck up with diesel and it drove home fine. Later that afternoon left the house and got half mile down the road and the truck just shut off with no warning lamps or message. When this happened, you could not steer the truck and the brakes barley worked, now after the truck cut off a message came to shift in neutral. I was lucky no one was on the road at that time. Now had this happened the day before when I was coming home pulling a 40ft fifth wheel, this could have been catastrophic. When this fuel pump module goes out you have no warning the truck cuts off and you have no steering or brakes. This module needs to be recalled, and something else done to have some kind of warning before everything shuts off. People get these trucks to pull things and sooner than later Chevrolet will be answering to a fatality due to this fuel module, this does not need to be ignored till this happens.
NHTSA complaint #11747679 — an unverified report by a vehicle owner.
This truck was parked on a job site, on a flat parking lot over blacktop, doing a regen for the 5th time in just a few days. The truck had 4,000 miles on it. When it completed the regen, we shut the truck off. Within 15 minutes the truck was fully engulfed in flames. A fire investigator looked at it and determined the fire started in the engine bay, below the master cylinder. He said this was a GM problem. As this truck was a replacement truck, for another broken down truck, we were outside the auto coverage on our insurance. The business property is covering the tool loss, and said it isnt worth going after GM as they make it impossible. I know this isnt the only vehicle this has happened to, and they simply refuse to even answer. I want to file a formal complaint against GM, and want them to cover the loss, the loss of use. This is a safety matter as this could have happened driving down the road and caused loss of life.
NHTSA complaint #11736265 — an unverified report by a vehicle owner.
Service engine light kept coming on the dash, and the code came back to a faulty DEF heater. My truck had a reduced power countdown on the dash indicating the truck was going go to into limp mode after x amount of miles. On warmer days the code would go away and there would be no reduced power. The vehicle was diagnosed at a GM dealership and confirmed the DEF heater was bad, but was notified that there is a bulletin with GM for this issue occurring in many other diesel trucks. My safety was put at risk due to the rapidly changing reduced speed milage, at any point it could drop from 100miles, to 10 miles until reduced speed. This could cause an instant car accident while driving if the truck were to randomly slow down to a speed much slower than the speed limit. IE- driving on the north way (65 speed limit) and having the speed drop to 5mph unexpectedly when you just had over 100 miles to reduced speed.
NHTSA complaint #11719345 — an unverified report by a vehicle owner.
My 2021 chevy 3500hd diesel had the engine light come on and the service emissions system popped up in the info screen. It said in so many miles speed would be limited. I took it to the dealer and they said the def tank would need replaced because the tank wiring connector overheated and would cost me over $2k.
NHTSA complaint #11716547 — an unverified report by a vehicle owner.
Def pump and heater module had burned terminals. This caused failure to the def pump and heater module. This was the second instance of this happening on this truck in roughly 40,000 miles. Burned terminals can start electrical fires that are a danger to occupants and others in the vicinity. Failure of this system forces a drop in speed after so many miles that make you a danger on the road.
NHTSA complaint #11715205 — an unverified report by a vehicle owner.
Email Subject I am reporting a serious safety-related defect involving sudden and complete vehicle shutdown while driving in a 2024 Chevrolet Silverado EV RST. Component/System Involved: The failure appears related to the 12-volt electrical system and associated vehicle control electronics. When the vehicle detects the 12V battery as dead or critically low, it immediately disables propulsion and control systems. The exact failed component is UNKNOWN. The vehicle is available for inspection upon request. Incident Description: This failure has occurred twice under similar conditions (ambient temperature approximately 25°F). On November 28, 2024 and again on January 2, 2026, after driving approximately two blocks at low residential speeds, the vehicle abruptly and completely shut down while in motion. In both incidents, the shutdown was immediate, without warning, and accompanied by a loud thud and an extremely abrupt stop. Safety Risk: In both incidents, the vehicle became completely immobilized in the roadway. I was unable to steer to the side of the road, restart the vehicle, or shift it into gear to move it out of traffic. This created a significant risk of collision. A similar failure at highway speeds could result in a severe or fatal crash. Warnings or Prior Symptoms: No warning lamps, messages, alerts, or other symptoms appeared prior to either shutdown. Problem Confirmation or Reproduction: The issue has occurred twice under cold-weather conditions. Inspections: After the first incident, the 12V battery was inspected and no issues were found. Following the second incident, the vehicle is currently being inspected at a Chevrolet dealership. No police or insurance inspections were performed. This behavior suggests the vehicle lacks a fail-safe or degraded-operation mode for 12V system failure and instead performs an immediate shutdown while in motion, which may represent a serious safety defect warranting investigation.
NHTSA complaint #11709144 — an unverified report by a vehicle owner.
Exhaust filter plugged due to turbo not working properly. Been at dealership going on 7 weeks This is the 3rd new vehicle we have had this has happened to.
NHTSA complaint #11697982 — an unverified report by a vehicle owner.
Driving at hiway speed and towing a 40' travel trailer the transmission failed and put my family in grave danger. GM is aware of this issue as they have issued a service bulletin due to an engineering flaw.... ( transfer case input and out put shaft failure) This needs to be a recall before someone is killed or injured ( wheels locking up at hiway speeds)
NHTSA complaint #11694954 — an unverified report by a vehicle owner.
The contact owns a 2024 Chevrolet Silverado 3500. The contact stated that while driving at various speeds, the vehicle hesitated, and the transmission failed to properly shift. The vehicle was taken to the local dealer, who discovered metal shavings inside the fuel filter and diagnosed that the High-Pressure Fuel Pump was faulty and needed to be replaced. The high-pressure fuel pump was replaced, and the vehicle was repaired. Later, while hauling a trailer on the highway, the vehicle unexpectedly stalled. The vehicle was towed to the dealer, who diagnosed that the fuel pump control module had failed and needed to be replaced. The vehicle was repaired. The manufacturer was notified of the failure, but no assistance was offered. The failure mileage was 19,000.
NHTSA complaint #11682084 — an unverified report by a vehicle owner.
The contact owns a 2024 Chevrolet Silverado 3500. The contact stated that while driving at various speeds, the vehicle hesitated, and the transmission failed to properly shift. The vehicle was taken to the local dealer, who discovered metal shavings inside the fuel filter and diagnosed that the High-Pressure Fuel Pump was faulty and needed to be replaced. The high-pressure fuel pump was replaced, and the vehicle was repaired. Later, while hauling a trailer on the highway, the vehicle unexpectedly stalled. The vehicle was towed to the dealer, who diagnosed that the fuel pump control module had failed and needed to be replaced. The vehicle was repaired. The manufacturer was notified of the failure, but no assistance was offered. The failure mileage was 19,000.
NHTSA complaint #11682084 — an unverified report by a vehicle owner.
The contact owns a 2015 Chevrolet Silverado 3500. The contact stated that while driving 65 MPH, the message "Fuel Filter Needed to be Replaced" followed by the "Engine Power Reduced" were displayed on the instrument panel. The contact then stated that fuel started leaking from the vehicle and the vehicle stalled. The contact was left stranded in the middle of the road; a tow truck was called, and the vehicle was towed to an independent diesel mechanic. The mechanic performed a diagnostic test, and the contact was informed that the fuel pump had disintegrated which caused debris from the fuel pump to leak into the fuel system. The contact was provided an estimate to replace the fuel pump, fuel pump filter, fuel pump housing, and the fuel injectors. The manufacturer was notified of the failure and referred the contact to the NTHSA Hotline to file a complaint. The vehicle had yet to be repaired. The failure mileage was approximately 270,000.
NHTSA complaint #11666246 — an unverified report by a vehicle owner.
The 2023 Chevy High Country Diesel vehicle for 89,000 has failed tremendously, without any warning whatsoever. I've had my vehicle serviced on a 6 to 8 weeks bases at the dealership. on March 28, 2025 I was driving in SD and the truck just failed all the suddenly. The information stated to shift to neutral and restart which I did. The truck never started and had to be towed. The first diagnosis was the high pressure fuel pump which contaminated the entire fuel systems with metal shavings. Thereby, the CP4 failed and damage all components of the fuel system costing 11,750.00 for the repair. In addition to this, during further inspecting the shop informed me the engine camshaft and lifter were also an issued and contributed to the dilemma. I then got General Motors involved informing them that now way possible this should have transpired with a new truck having only 126,000 miles. I stated this is nothing for a diesel engine and something was not adding up. At the time I wasn't aware of all the issue General Motors were having with the trucks and suvs. I told them that no way can I pay 31,000.00 for a repairs on a new practically new truck I purchased brand new. They need to honor these problematic vehicles.
NHTSA complaint #11658291 — an unverified report by a vehicle owner.
The contact owned a 2018 Chevrolet Silverado 3500 Commercial Vehicle. The contact received notifications of NHTSA Campaign Numbers: 21V496000 (Equipment) and 23V047000(Fuel System, Diesel) and would like to be removed from the recall distribution list because the vehicle was totaled. The manufacturer was contacted.
NHTSA complaint #11639065 — an unverified report by a vehicle owner.
The contact owns a 2013 Chevrolet Silverado 3500. The contact stated while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to the independent mechanic where it was diagnosed with failed temperature sensors and a failed heating element in the diesel exhaust fluid (DEF) tank. The contact was informed that the heating element and the temperature sensors needed to be replaced. The vehicle was not repaired. In addition, the contact stated that an unknown repair was performed four years ago on the diesel exhaust fluid (DEF) tank. The manufacturer was made aware of the failure but did not assist. The contact was advised to contact the NHTSA Hotline to report the failure. The failure mileage was approximately 39,639.
NHTSA complaint #11638285 — an unverified report by a vehicle owner.
On [XXX] while traveling down [XXX] in VA I experienced a catastrophic Bosch CP4 Fuel Pump Failure. Vehicle was towed to Marion Auto Group in Marion, VA and kept for 5 weeks to repair fuel system. We paid $6,500 once we were told the repairs were complete and picked the vehicle up. Within 50 miles of driving, the fuel system error lights/codes began again and the service engine light came on. We called Marion Auto Group, they told us it was warranted for 24 months for parts and labor. We could take it to any Chevy dealer and have it looked at. We made an appt with our local Chevy dealer, Joe Bowman Chevrolet in Harrisonburg, VA. They kept the vehicle for approximately 5-6 weeks. Told us daily about the faulty repairs that Marion Auto Group had made, corrected the faulty repairs, with pictures, videos and even a coffee cup full of bad bolts and weld pieces that they replaced. Marion Auto Group agreed to pay Joe Bowman Chevrolet $5,500 in reimbursement for the work they performed to correct Marion Auto Groups work. When I got in the truck to bring it home and started it, the service engine light came on. They pulled it back in the shop, ran a diagnostic and said we needed some type of sensor ($900) so we scheduled an appt to have that done. Then we took the truck to Tennessee, fuel system failure lights and codes immediately came on. When I stopped to eat, it wouldn't start back. Took the truck to Tarr Chevrolet in Jefferson City TN, they diagnosed it as needing a new fuel line (from prev faulty fuel system) changed it ($1,700) and we headed back home with all the fuel system warning lights flashing again. Took it back to Joe Bowman Chevrolet in Harrisonburg where it's been sitting for over 7 weeks while GM decides if they should cover the entire new fuel system that it needs again ($19,000) because it's never been properly repaired since the initial catastrophic failure. Almost 7 months and $14,,600 in previous repairs.......Please HELP US! INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT
NHTSA complaint #11634518 — an unverified report by a vehicle owner.
Injector #4 connector harness issue- Known issue on the 6.6L duramax. Driving with my children for Christmas pickup and power reduction occurred while passing another car on the road. Causing us to hit the breaks as the truck wouldn’t allow us to pass timely. Known harness issue by GM and instead of covering I had to pay to have a new connector spliced in. Multiple warning lights. Check engine, Emissions warning, Reduced power, Traction control, parking brake
NHTSA complaint #11632370 — an unverified report by a vehicle owner.