GMC · Known Issues
2016 GMC Sierra 2500HD Problems: 9 Known Issues
2016 model year · 2,880+ 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 · 2,880+ 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 2,880+ owner reports, the 2016 GMC Sierra 2500HD has 9 documented known issues, with 7 rated critical. The most serious are CP4.2 High-Pressure Fuel Pump Catastrophic Failure ($8,000-$18,000 repair), LML Duramax EGR Cooler and EGR Valve Failure ($1,200-$3,500 repair), Allison 1000/2000 Transmission TCM Failure and Harsh Shifting ($300-$4,500 repair), 6.0L V8 Excessive Oil Consumption and AFM Lifter Wear ($400-$7,000 repair), Engine Vacuum Pump Output Decay Reducing Power Brake Assist (Recall 19V645000) ($0-$700 repair), Roof-Rail Air Bag Inflator End Cap Detachment and Rupture (Multiple NHTSA Recalls) ($0-$0 repair) and LML DEF Tank Heater, DEF Injector and NOx Sensor Failures Triggering Speed-Limited Limp Mode ($400-$2,500 repair). The most commonly reported issue is CP4.2 High-Pressure Fuel Pump Catastrophic Failure with 920 owner reports. Across all issues with published estimates, repair costs range from $250 to $18,000. DIY maintenance guides at au7o.io.
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According to Au7o's analysis of 2,880+ owner reports, the 2016 GMC Sierra 2500HD has 9 documented issues. The most frequently reported are: CP4.2 High-Pressure Fuel Pump Catastrophic Failure, LML Duramax EGR Cooler and EGR Valve Failure, Allison 1000/2000 Transmission TCM Failure and Harsh Shifting. Of these, 7 are rated critical and should be addressed promptly.
The 2016 GMC Sierra 2500HD has 9 known issues documented across 2,880+ owner reports. 7 issues are rated critical: CP4.2 High-Pressure Fuel Pump Catastrophic Failure and LML Duramax EGR Cooler and EGR Valve Failure and Allison 1000/2000 Transmission TCM Failure and Harsh Shifting and 6.0L V8 Excessive Oil Consumption and AFM Lifter Wear and Engine Vacuum Pump Output Decay Reducing Power Brake Assist (Recall 19V645000) and Roof-Rail Air Bag Inflator End Cap Detachment and Rupture (Multiple NHTSA Recalls) and LML DEF Tank Heater, DEF Injector and NOx Sensor Failures Triggering Speed-Limited Limp Mode. 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 Sierra 2500HD issues range from $0 to $18,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, CP4.2 High-Pressure Fuel Pump Catastrophic Failure, typically costs $8,000-$18,000 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
The Bosch CP4.2 high-pressure fuel injection pump used on the 2011-2016 LML and 2017-2020 L5P Duramax diesel engines is prone to catastrophic failure that destroys the entire fuel injection system. Unlike its predecessor the CP3, the CP4.2 lacks a roller element and relies solely… Repairs typically run $8,000-$18,000. Severity: high.
The LML Duramax EGR (exhaust gas recirculation) cooler is prone to coolant leaks internally, allowing coolant to enter the intake manifold and combustion chambers. Coolant in the intake causes white smoke, rough running, and potential hydrolocking of cylinders. The EGR valve also… Repairs typically run $1,200-$3,500. Severity: high.
The Allison 1000 (gas) and Allison 2000 (diesel) 6-speed automatic transmissions used in Sierra 2500HD/3500HD are widely regarded as extremely durable, but the Transmission Control Module (TCM) and solenoid pack do develop faults. Common issues include harsh 1-2 shifts, transmiss… Repairs typically run $300-$4,500. Severity: high.
The 6.0L L96 V8 gasoline engine in Sierra 2500HD (non-diesel) suffers from Active Fuel Management (AFM) lifter failures similar to the 5.3L in Sierra 1500 — though less frequently due to the higher displacement. More commonly, 6.0L engines exhibit excessive oil consumption (1 qt… Repairs typically run $400-$7,000. Severity: high.
On gasoline-engine 2014-2018 Sierra 2500HD trucks the belt- and cam-driven vacuum pump that supplies the brake booster loses output as debris and oil sludge accumulate on its internal filter screen. As vacuum falls the booster provides progressively less assist, so pedal effort r… Repairs typically run $0-$700. Severity: high.
The side-curtain (roof-rail) air bag inflators fitted to GMT900-era and 2015-2019 Sierra 2500HD cabs can have the inflator end cap detach during deployment, releasing compressed gas into the headliner and propelling the cap and headliner components into the occupant compartment. Repairs typically run $0-$0. Severity: high.
The 2011-2016 6.6L Duramax RPO LML added selective catalytic reduction, and the aftertreatment hardware is the engine's most frequent expense. The DEF tank heater and level/quality sender assembly fails often, the DEF (reductant) injector crystallizes and clogs, and pre-2015 NOx… Repairs typically run $400-$2,500. Severity: high.
Sierra 2500HD 4WD trucks use a front axle disconnect system with an electronic actuator and Integrated Wheel End (IWE) hubs. The actuator motor and position sensor commonly fail between 80,000-120,000 miles, causing the 4WD system to not engage, to partially engage (binding and v… Repairs typically run $350-$1,800. Severity: medium.
The Garrett variable-geometry turbocharger used on the LBZ, LMM and LML Duramax controls boost by pivoting vanes on a unison ring inside the turbine housing. Soot and carbon bake onto the ring over time and it begins to bind, so the actuator can no longer move the vanes to the co… Repairs typically run $250-$2,800. Severity: medium.
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.