Other Fuel System Problems of Chevrolet Silverado 3500 - part 1

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.

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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.

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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.

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.

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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.

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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.

See all problems of the 2025 Chevrolet Silverado 3500 🔎.

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.

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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.

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).

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.

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.

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Received a code p10d9. Infotainment center says 157 miles until 65 mph max speed. Dealer has no idea what’s wrong.

2nd time I’ve had to replace def heater and tank. Truck goes into limp mode and limits the speed leaving a person stranded.

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.

I was driving the truck and the dashboard said fuel filter at 0 % entering low power mode. The truck did not accelerate at all and stopped running within 5 minutes . The repair cost almost 9000. 00 for a 100. 00 fuel filter.

See all problems of the 2016 Chevrolet Silverado 3500 🔎.

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.

Vehicle regularly stalls while driving, going down hills and any random time at highway speeds, while in traffic, while stopped at traffic controls. This problem happens repeatedly and is apparently related to the “pump mounted driver”, which is prone to failure due to inadequate design for the use and environment. It creates random failures of the pump to deliver fuel.

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Bosch cp4 fuel pump failed 400 miles from home leaving us stranded. We were towed in and spent thousands of dollars and 5 weeks to have the truck repaired. Only warning was that the truck was losing power and barely got off the road.

Cp4 fuel pump failed while driving 250 miles from home. It was towed in and diagnosed, resulting in over $12,000. 00 dollars to replace fuel system due to metal pumped into fuel system. The mechanic sent the pump back as a core charge. We were stranded and freezing with our dog and towed in after several hours. The only warning was the vehicle was reducing power and I was able to get off the highway.

I believe my def heater has stopped working and my full def tank is now frozen. I’m now stranded in the middle of south dakota in -29 degree weather. My truck will not drive. Or idle for the heater to keep me warm because the def is required for engine to run.

Probable high pressure fuel pump (cp4) failure resulting in the vehicle stalling without warning. This event has not yet occurred, however due to the high number of vehicles involved in the stellantis recall which are using the same cp4 pumps which are known to fail, I am scared to drive my truck as the cp4 pump may fail at any time. I have spoken to many other gm truck owners who have experienced this failure and it has cost them tens of thousands of dollars. Please open a recall for the cp4 high pressure fuel pump for 2011-2016 gm trucks using this hpfp. Thank you,.

Our diesel fuel pump failed unexpectedly and without any notice while pulling a fifth wheel camper on a state highway in ohio. The engine stopped completely (we were coasting within seconds). We were in a one-lane construction zone, and had it not been for a paved median, I would have been unable to pull off in this construction zone. Fortunately, I had enough momentum to get off the road and was able to exert enough pressure on the brakes manually to stop. In reading about this issue, it is clear that there are known problems with this fuel pump. My cost to repair this defective part will be about $11,500 and will require a 12 hour round trip back to ohio to pick-up the vehicle after a two-week repair.

See all problems of the 2012 Chevrolet Silverado 3500 🔎.

Check engine light came on followed almost immediately with an onstar warning to service the engine and transmission within 7 days. Took truck to dealer. They diagnosed problem was fuel system contamination. Hole was found on the inner mesh liner of the fuel filter which allowed water and a sludge like material to get into the fuel system.

The def system on this vehicle has failed three times since we bought it in 2021. The weather was not pleasant and in one case it was extremely dangerous. The def system froze up and fortunately I was able to limp it into a dealer who managed to get it working again but not after losing half a day and spending a couple hundred dollars. The second time a sensor failed and I was able to reset the system myself via removing all the electricity from the vehicle and doing what they call a shady tree reset. The third time the vehicle went into limp mode on us was when a sensor failed and the def pump failed at the same time. Chevy refused to help us cover the cost of repairs and refuses to replace the defective system. The vehicle might be over ten years old but it is like showroom new, it only had 20,000 miles on it in 2021 when we bought it and the previous owner took very good care of the truck. The vehicle now only has 32,000 miles on it. Our main argument is that chevy aka gm knows about the defective systems and refuses to replace them. I have been in the transportation industry for a good part of my life and I know vehicles, especially diesel operated vehicles. The def systems are a complete joke and need to be removed especially for people who live in very cold climates.

See all problems of the 2011 Chevrolet Silverado 3500 🔎.

Gm recall n2123544170 dpf regeneration temperature /def heater for cold weather operation to keep def from freezing and also for thawing frozen def. . . Dealer to replace def tank and internal heating element. . . Dealer was unable to give a time line for replacement parts needed to fix truck. (parts are back ordered)so truck ecm=electonic control module. Throws trouble code to reduce engine power that starts taking away engine power at 65 mph. . . Then 55 mph. . . Then 45. . . All the way down to 5 mph. This can happen at any time or anywhere that can result in possible accidents. . . ! gm needs to make this a priority as thousand of vehicles are affected!.

Friday October 8th 2021, my truck shut off in the middle of chesnee SC within 1/4 mile after filling up with diesel fuel at the hot spot in chesnee. I had it towed to burns Chevrolet in gaffney SC for analysis. They determine it was the result of contamination in the fuel and that is not a warranty issue. I would agree that is not the responsibility of Chevrolet and I authorized them to make the repairs. They did what you would normally expect with the exception of one thing. They came back and said they had to replace the fuel transfer line between the fuel tanks. Said it was kinked. I questioned how water in the fuel could cause that to happen but they said the contamination was the root cause and I had to pay to fix that as well. I requested a sample of the contamination and all parts replaced. That charge was included on the invoice and I paid it. There are other issues with the quality of the service which included returning the next day because the water contamination light came on again. They had to bleed the newly installed fuel filter there in the parking lot and the light went off. When I got home and inspected the replaced parts, I found that the fuel transfer line not only was kinked, but also ruptured. I just retired from an oem as a quality specialist, and many of my parts were safety critical. I would be willing to bet that the tier 1 supplier does not have a ruptured fuel line ranked very high on their fema plan due to the probability of water causing a kink little on a rupture, but according to the Chevrolet technician that was the root cause, so they own it. I called Chevrolet corporate and informed them of my plan to report this incident. They opened an incident report, but failed to take any action to address my concerns. You will find when you check the dealers repairs to this vehicle, it has had several issues related to fuel problems. Due to space limitations on this page, I cannot tell you the whole story. Contact me and I can explain furthe.

The contact owns a 2015 Chevrolet Silverado 3500. The contact stated that while driving approximately 40 mph, the vehicle stalled without warning. The contact coasted to the side of the roadway. The vehicle was towed to pinegar Chevrolet Buick GMC of branson (163 adair rd, branson, mo 65616, (866) 311-4731) to be diagnosed. The contact was informed that the fuel system was defective. The vehicle was not repaired. The manufacturer was contacted and notified of the failure. The manufacturer informed the contact of an ongoing class action lawsuit however, the VIN was not included. The approximate failure mileage was 114,000.

Tl- the mechanic called on behave of the vehicle owner of a 2018 Chevrolet silverado, regarding NHTSA campaign number: 19v088000 (fuel system, gasoline). The vehicle was taken to local dealer champion Chevrolet (located at 800 kietzke ln, reno, nv 89502, (775) 786-3111) exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The part was not available for the repair. The vehicle has not experienced a failure. Parts distribution disconnect. Dp.

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Recall was announced Feb 7, 2019 my complaint is why is it taking so long to obtain parts and get the vehicle repired it has been three months.

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The contact owns a 2016 Chevrolet Silverado 3500. The contact received notification of NHTSA campaign number: 19v088000 (fuel system, gasoline). The contact called carl black Chevrolet Buick GMC at (888) 457-2417 (located at 1110 roberts blvd NW, kennesaw, GA 30144) and was informed that the parts were not available. The manufacturer was made aware of the issue and was not able to confirm when the parts were to become available. The contact had not experienced a failure. VIN tool confirms parts not available.

Tl the contact owns a 2017 Chevrolet Silverado 3500. The contact received notification of NHTSA campaign number: 19v088000 (fuel system, gasoline); however, the manufacturer exceeded a reasonable amount of time for the recall repair. The contact called the manufacturer and they disconnected the call. The dealer was not contacted. The contact had not experienced a failure. VIN tool confirms parts not available.

Cp4 high pressure fuel pump failed causing loss of motive power (lomp) in oct of 2018. Truck became hard to steer and brake but I was traveling at a lower speed. Had it of been 1 hour later I would have been at freeway speeds pulling a 13000lbs trailer. I had the truck towed to a local dealer where they diagnosed the truck as having a failed cp4 high pressure fuel pump made by bosch. They informed me that the entire fuel system would have to be replaced do to the large amount of metal contaminants that this catastrophic failure produces and spreads though out the entire system. The total cost for the repairs were not covered under any type of warranty or recall and had to be paid entirely out of pocket. Not only was this a huge inconvenience as I was trying to leave town for a vacation it was very very expensive. I still can not understand why there has never been a recall on this issue. I think it can be related to a safety issue as a lomp. I believe gm knew that the cp4 pump was and could be a faulty product but continued to use it.

Experienced known chuggle issue at only 200 miles on the new vehicle. Information regarding this known issue by gm below (known issue since 2017). #pip5480: hesitation, bump or chuggle involved region or country: north America additional rpo/s: 6. 6 l5p condition: customer concern may be of a hesitation, bump, chuggle, jerk or a feeling of harshness under the following conditions:  1. Vehicle speed in the range of 25-45 mph.  2. Light accelerator pedal tip-in or tip-out maneuver.  3. Transmission in 3rd gear. Cause under investigation. Gm engineering is aware of this concern and is working on a resolution (since 2017 when l5p power plant was released yet they keep releasing vehicles with this issue).

Tl- the contact owns a 2015 Chevrolet Silverado 3500. The contact stated that while pulling a horse trailer and driving approximately 55 mph on the highway the vehicle suddenly shut off. The vehicle was towed to the local dealer bachman-bernard located at 3365 e. Andrew johnson hwy. Greeneville TN. Who diagnosed that the failure was caused by a faulty fuel filter. The vehicle was repaired. The manufacturer was notified of the failure but no assistance was offered. The failure mileage was 33,922. Jft.

The contact owns a 2005 Chevrolet Silverado 3500. While driving 70 mph, the vehicle stalled without warning. The contact was unable to restart the vehicle. The vehicle was towed to lucas Chevrolet (4323, 101 s james campbell blvd, columbia, TN 38401, (931) 398-5092) where it was diagnosed that the fuel system needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 220,000.

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