GMC · Known Issues
2016 GMC Savana Problems: 8 Known Issues
2016 model year · 780+ owner reports · Updated September 2026
2016 · All trims · All engines
Choose the year and equipment for your written issues and visual request.
2016 model year · 780+ owner reports · Updated September 2026
2016 · All trims · All engines
Choose the year and equipment for your written issues and visual request.
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According to Au7o's analysis of 780+ owner reports, the 2016 GMC Savana has 8 documented known issues, with 4 rated critical. The most serious are Fuel Pump Module Failure and Hard Start / Stalling ($350-$900 repair), AFM Lifter Failure on V8 Vortec/EcoTec3 Engines ($3,500-$8,000 repair), Cutaway Rear HVAC Blower Circuit Corrosion at Left B-Pillar - Fire Risk (Recall 23V-247) ($0-$0 repair) and Driver's Door Power Window Switch Liquid Intrusion and Corrosion - Fire Risk (Recall 18V-295) ($0-$0 repair). The most commonly reported issue is Fuel Pump Module Failure and Hard Start / Stalling with 430 owner reports. Across all issues with published estimates, repair costs range from $100 to $8,000. DIY maintenance guides at au7o.io.
STRUCTURE:BODY:DOOR
General Motors LLC (GM) is recalling certain 2025 Chevrolet Express and GMC Savana vans. The impact beam located in the driver's side door may have improper welds.
TIRES:SIDEWALL
General Motors, LLC (GM) is recalling certain 2025-2026 Express Cutaway, and 2025-2026 Savana Cutaway vehicles. These vehicles may be equipped with a tire with sidewall damage.
SEATS:FRONT ASSEMBLY:HEAD RESTRAINT
General Motors LLC (GM) is recalling certain 2025 Chevrolet Express and GMC Savana vehicles. The front passenger seat head restraint may have been improperly welded to the seat frame.
STEERING
General Motors, LLC (GM) is recalling certain 2025-2026 Express, and 2025-2026 Savana vehicles. The steering gear assembly may have a nut that was not properly tightened.
POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE:SOFTWARE
General Motors, LLC (GM) is recalling certain 2022-2023 Chevrolet Express and GMC Savana vehicles. Incorrect software in the transmission control module (TCM) may result in harsh shifting, reduced power, unintended deceleration, rear wheel lockup, or cause the vehicle to move in an unintended direction.
+ 3 more recalls. Check all on NHTSA.gov
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According to Au7o's analysis of 780+ owner reports, the 2016 GMC Savana has 8 documented issues. The most frequently reported are: Fuel Pump Module Failure and Hard Start / Stalling, AFM Lifter Failure on V8 Vortec/EcoTec3 Engines, Cutaway Rear HVAC Blower Circuit Corrosion at Left B-Pillar - Fire Risk (Recall 23V-247). Of these, 4 are rated critical and should be addressed promptly.
The 2016 GMC Savana has 8 known issues documented across 780+ owner reports. 4 issues are rated critical: Fuel Pump Module Failure and Hard Start / Stalling and AFM Lifter Failure on V8 Vortec/EcoTec3 Engines and Cutaway Rear HVAC Blower Circuit Corrosion at Left B-Pillar - Fire Risk (Recall 23V-247) and Driver's Door Power Window Switch Liquid Intrusion and Corrosion - Fire Risk (Recall 18V-295). 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.
Repair costs for known GMC Savana issues range from $0 to $8,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Fuel Pump Module Failure and Hard Start / Stalling, typically costs $350-$900 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
The GMC Savana (and Chevrolet Express) fuel pump module is known for premature failure between 80,000-140,000 miles, often stranding drivers without warning. The in-tank electric fuel pump motor burns out or the sending unit becomes erratic. Running the tank consistently below 1/… Repairs typically run $350-$900. Severity: high.
GMC Savana vans equipped with 4.8L (L20), 5.3L (LM7), and 6.0L (L96) V8 engines with Active Fuel Management suffer the same AFM lifter collapse problem documented across the entire GM full-size truck/van lineup. The collapsible AFM lifters on deactivation cylinders fail between 6… Repairs typically run $3,500-$8,000. Severity: high.
Savana Cutaway chassis are built with an unused wiring circuit at the lower left B-pillar so that a final-stage upfitter can install an optional rear HVAC blower. When the upfitter leaves that circuit's connectors or cut wire ends unsealed, moisture and road contamination corrode… Repairs typically run $0-$0. Severity: high.
On 2014-2017 Savana and Express vans with power windows, liquid spilled or blown onto the driver's door armrest can enter the master power window switch. The contamination corrodes the switch contacts, raising electrical resistance in the circuit; the resulting heating can start… Repairs typically run $0-$0. Severity: high.
When the Savana 2500/3500 moved to the 6L90 six-speed for 2010, a new failure appeared that the old 4L80E did not have. GM's own service information for 2010-2014 Express and Savana vans with the 6.0L flex-fuel V8 and 6L90 acknowledges that torque converter clutch friction materi… Repairs typically run $900-$5,000. Severity: medium.
Savana and Express bodies rot in a predictable pattern: rocker panels beneath the front and sliding doors, the bottoms of the doors themselves, the lower rear quarters at the wheel arches, and the lower skins of the side cargo and rear doors. The doors rust from the inside out -… Repairs typically run $400-$5,000. Severity: medium.
On the 4.8L, 5.3L and 6.0L Vortec V8s the exhaust manifold bolts - almost always the ones at the extreme front and rear of each cylinder head - snap from repeated thermal cycling, letting the manifold lift off the head. The classic symptom is a loud tick or 'exhaust leak' ticking… Repairs typically run $600-$2,200. Severity: medium.
The rear cargo doors and sliding side door hinges wear out from the weight of the doors and constant commercial use. Doors sag, become difficult to close, and the weatherstripping no longer seals properly. Repairs typically run $100-$400. Severity: low.
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.