What is the 2007-2019 GMC Sierra 3500HD Silverado/Sierra 3500HD Frame Corrosion and Rust-Through (Salt Belt)?

The fully boxed steel frame on 2007–2019 Sierra 3500HD trucks operating in northern and salt-belt states is susceptible to severe corrosion, particularly around crossmember mounting points, rear spring hanger brackets, and fuel/brake line routing areas. NHTSA received numerous co… Repairs typically run $500-$8,000. Severity: critical.

What is the 2011-2019 GMC Sierra 3500HD Hydroboost brake assist loss due to power steering pump/hose failure?

On Sierra 3500HD trucks equipped with hydroboost, a loss of power steering hydraulic pressure can also reduce brake assist. Owners report a sudden hard brake pedal and increased stopping distance, often accompanied by power steering noise or intermittent steering assist. NHTSA co… Repairs typically run $350-$1,600. Severity: critical.

2015 GMC Sierra 3500HD Problems: 21 Issues Every Owner Should Know

2015 model year · 3,560+ owner reports · Updated May 2026

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According to Au7o's analysis of 3,560+ owner reports, the 2015 GMC Sierra 3500HD has 21 documented known issues, with 8 rated critical. The most serious are CP4.2 High-Pressure Fuel Pump Catastrophic Failure ($10,000-$18,000 repair), DPF (Diesel Particulate Filter) Clogging and Regeneration Failure ($300-$3,500 repair), Turbocharger VGT Vane Sticking and Boost Control Failure (Duramax LML/L5P) ($200-$3,500 repair), Duramax Water Pump Failure and Coolant Leak ($400-$1,200 repair), Trailer brake controller / integrated trailer brake module malfunction ($80-$900 repair), Allison 1000 Transmission Control Module and Sensor Failures ($500-$3,500 repair), Diesel Injector Failure Causing White Smoke and Rough Running ($600-$5,000 repair) and Rear Leaf Spring Breakage Under Heavy Loads ($400-$1,500 repair). The most commonly reported issue is CP4.2 High-Pressure Fuel Pump Catastrophic Failure with 440 owner reports. Across all issues, repair costs range from $80 to $18,000. at .

All 21 Known Issues

When Issues Typically Appear

Trailer brake controller / integrated trailer brake module malfunction

5K-90K

A/C condenser leak leading to loss of refrigerant and warm air

20K-90K

Front Differential Actuator Failure Causing 4WD Engagement Problems

40K-130K

Rear axle pinion seal leak and differential fluid loss (AAM 11.5/11.8)

40K-160K

Blend door actuator failure causing temperature/airflow control problems

40K-140K

Allison 1000/2000 Series Transmission Torque Converter Shudder

50K-180K

DPF (Diesel Particulate Filter) Clogging and Regeneration Failure

60K-150K

Glow plug control module / glow plug circuit faults causing hard cold starts (Duramax)

60K-180K

Duramax Water Pump Failure and Coolant Leak

70K-160K

Turbocharger VGT Vane Sticking and Boost Control Failure (Duramax LML/L5P)

80K-200K

050K100K150K200K mi

Community Reported

440 owners

On the 2011-2020 GMC Sierra 3500HD, the Sierra 3500HD Duramax diesel uses the same Bosch CP4.2 high-pressure fuel pump as the 2500HD. The pump is prone to catastrophic failure that destroys the entire fuel injection system (all 6 injectors, fuel rails, return lines). The 3500HD is often used for heavier towing and work applications, which places more sustained load on the high-pressure fuel system and may accelerate CP4.2 wear. Total system replacement costs $10,000-18,000. A CP3 conversion kit (Fleece FPE-CP3K-LML or FPE-CP3K-L5P) is strongly recommended as a preventive upgrade on any high-mileage Sierra 3500HD Duramax.

This issue also affects: Alfa Romeo Giulia, Alfa Romeo Stelvio, Chevrolet Silverado 2500HD

Common Symptoms

Sudden hard start or no-start
Loss of power under towing load
Rough running on multiple cylinders
Metal shavings in fuel filter
Fuel rail pressure codes P0087, P0191
Reduced Engine Power message

How to Fix

Replace entire fuel system on failure. Preventive CP3 conversion kit (Fleece FPE-CP3K-LML for LML, FPE-CP3K-L5P for L5P). Install FASS lift pump. Never run below 1/4 tank.

What Owners Are Using

Parts and tips from 440+ owners who fixed this issue

UpgradeFleece Performance FPE-CP3K-L5P CP3 conversion kit for 2017-2020 L5P Duramax (Sierra 2500HD/3500HD) — replaces the failure-prone CP4.2 with the proven CP3 pump design. Requires a tuner adjustment for fueling command changes. Essential preventive upgrade for any 3500HD used for heavy towing or commercial duty. (Fleece Performance #FPE-CP3K-L5P)
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UpgradeFASS Titanium TSDP07 150GPH diesel lift pump — feeds consistent, clean, air-free diesel to the CP4/CP3. Provides critical pump protection especially under heavy towing where fuel draw is highest and pump starvation risk increases. Strongly recommended alongside any CP3 conversion on Sierra 3500HD. (FASS Fuel Systems #TSDP07150G)
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NoteSierra 3500HD operators using their trucks for gooseneck or 5th-wheel towing with the L5P Duramax should install the FASS lift pump and CP3 conversion before 80,000 miles. Sustained heavy towing with a fully loaded 30,000+ lb trailer stresses the CP4.2 significantly more than highway driving. CP4 failure while under a heavy tow creates a dangerous uncontrolled deceleration situation in addition to the $15,000+ repair bill.

Typical repair cost:$10,000 - $18,000

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High Confidence440 reportsLast reported by owners Feb 2026Reviewed Feb 2026

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295 owners

On the 2011-2022 GMC Sierra 3500HD, the variable geometry turbocharger (Garrett GT3788VA on LML, and similar VGT on L5P) used on 6.6L Duramax engines develops carbon buildup on the variable vanes, causing them to stick and resulting in loss of boost control. Owners report surging, lack of power under load, black smoke, and check engine lights. This is a widely documented issue in Duramax owner communities and referenced in multiple TSBs including 16-NA-026.

This issue also affects: Audi A3, Audi A6, Audi A8

Common Symptoms

Reduced power or hesitation under load, especially above 2000 RPM
Excessive black smoke from exhaust under acceleration
Boost pressure gauge reading lower than normal
Surging or inconsistent throttle response
Check engine light with boost-related codes

How to Fix

Turbocharger vane cleaning using BG Induction Service or equivalent upper-cylinder cleaner introduced through intake. Severe cases require turbo removal and manual vane cleaning or actuator replacement. Complete turbo replacement with remanufactured Garrett unit ($1,200–$2,500 part) is recommended if vanes are seized. Updated VGT actuator calibration via ECM flash per TSB 16-NA-026.

Typical repair cost:$200 - $3,500

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Medium Confidence295 reportsLast reported by owners Invalid DateReviewed May 2026

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110 owners

On the 2007-2019 GMC Sierra 3500HD Duramax, duramax-equipped Sierra 3500HD owners report hard starting, extended cranking, and rough idle in cold weather due to glow plug system faults. NHTSA complaints and service information commonly involve failed glow plugs, glow plug control module issues, or wiring/connector problems that trigger circuit DTCs and reduce preheat performance.

This issue also affects: Chevrolet Silverado 2500HD, Chevrolet Silverado 3500HD, Audi A3

Common Symptoms

Hard start or no-start in cold temperatures
Extended cranking time
Rough idle and white/gray smoke on startup
Check Engine light with glow plug circuit codes
Reduced power briefly after cold start

How to Fix

Scan for glow plug and control module DTCs, load-test the glow plugs, and inspect harness/connectors at the glow plug controller. Replace failed glow plugs and/or the glow plug control module as indicated, then clear codes and verify proper preheat operation. Use OEM glow plugs specified for the engine (LMM/LML/L5P vary by year).

Typical repair cost:$250 - $1,200

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Medium Confidence110 reportsLast reported by owners Invalid DateReviewed Apr 2026

On the 2011-2020 GMC Sierra 3500HD Duramax, the Duramax diesel Sierra 3500HD (2011+) equipped with the DEF/SCR emission system develops failures in the DEF tank heater, DEF quality sensor, and associated wiring. Wires to the DEF tank short out, and because they share a harness with the transmission, this can trigger both DEF and transmission warnings simultaneously. Cold weather operation exacerbates DEF system problems as the fluid crystallizes.

This issue also affects: Audi Q7, Chevrolet Silverado 3500HD, Dacia Duster

Common Symptoms

DEF warning message on dash
Reduced engine power / limp mode
Check engine light with SCR-related codes
Service Exhaust Fluid System message
Transmission warning alongside DEF warning (shared wiring)
DEF system not heating in cold weather

How to Fix

Scan the SCR/DEF system for stored DTCs and inspect the DEF tank harness where it runs with the transmission wiring, as chafed or shorted wires commonly cause both DEF and transmission warnings at the same time. Test the DEF tank heater, reductant quality/level sensor, and pump module; replace the failed heater or complete DEF tank header/sensor assembly as needed, repair damaged wiring with updated pigtails, clean any crystallized DEF contamination, and confirm proper heater operation and reductant quality readings with a scan tool. In cold-weather cases, verify the tank heater is drawing current and that the fluid lines are not frozen before condemning other components. Typical repair cost ranges from about $300-$800 for harness or heater repairs, and $900-$1,800 if the DEF tank/header assembly must be replaced.

What Owners Are Using

Parts and tips from 0+ owners who fixed this issue

UpgradeBluetooth OBD-II scanner for reading engine codes and monitoring live data (BlueDriver Bluetooth OBD2 Diagnostic Scan Tool)
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UpgradeQuality synthetic oil and filter combo for engine maintenance (Mobil 1 Full Synthetic Oil and Filter Bundle)
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Typical repair cost:$300 - $2,000

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On the 2008-2019 GMC Sierra 3500HD Duramax, the Allison 1000 transmission paired with the Duramax diesel in 2008-2015 Sierra 3500HD trucks has a high failure rate for the Transmission Control Module (TCM). A class action suit was filed covering these years. Additional issues include input/output speed sensor failures causing no-forward/reverse conditions, and certain 2012 trucks built with incorrect thrust bearings.

This issue also affects: Acura TL, Acura CL, Acura ILX

Common Symptoms

Intermittent no forward or reverse movement
Flashing PRNDL display
Range Shift Inhibited message
Harsh or delayed shifts
Transmission noise or whine
Check engine light with transmission codes

How to Fix

What Owners Are Using

Parts and tips from 0+ owners who fixed this issue

UpgradeQuality automatic transmission fluid for routine service (Valvoline MaxLife ATF Full Synthetic)
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UpgradeTransmission filter kit with pan gasket for complete fluid service (ATP Transmission Filter Kit)
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UpgradeOBD-II scanner with transmission live data for diagnosing shift issues (BlueDriver Bluetooth Pro OBD2 Scan Tool)
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Typical repair cost:$500 - $3,500

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310 owners

On the 2007-2020 GMC Sierra 3500HD, the Allison 1000 and 2000 series automatic transmissions paired with Duramax engines in the Sierra 3500HD exhibit torque converter clutch shudder during light throttle cruising between 40–65 MPH as the TCC applies and releases. This is caused by degraded transmission fluid, worn TCC friction material, or contamination in the hydraulic circuit. GM and Allison have acknowledged this issue through multiple fluid specification updates and TSB 07-07-30-022.

This issue also affects: Audi A4 Avant, Audi A4, Audi A6

Common Symptoms

Vibration or shudder between 40–65 MPH at light throttle
Shudder disappears under hard acceleration or deceleration
Transmission hesitation or clunk when TCC engages
Rough or inconsistent lockup feel during highway cruising
Transmission fluid with burnt smell or dark discoloration

How to Fix

Drain and refill with Allison-approved TES-295 or TES-468 fluid (Transynd or equivalent); do not use generic ATF. If shudder persists after fluid service, a complete torque converter replacement (remanufactured unit $400–$800) and valve body cleaning is required. GM TSB 07-07-30-022 outlines the fluid change procedure and updated fill volume specifications. Complete transmission fluid flush recommended every 50,000 miles for prevention.

Typical repair cost:$150 - $2,200

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Medium Confidence310 reportsLast reported by owners Invalid DateReviewed May 2026

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320 owners

On the 2011-2022 GMC Sierra 3500HD, the Duramax diesel DPF becomes clogged with soot under low-speed, short-trip, or heavy towing duty cycles that prevent complete passive regeneration. Owners report the truck entering limp mode, reduced power, and repeated active regen cycles that fail to fully clean the filter. GM TSB 14-06-04-003 addresses regen strategy calibration updates for LML and L5P engines.

This issue also affects: Audi Q7, Citroën Berlingo, Citroën C4

Common Symptoms

Reduced engine power / limp mode activation
DPF warning light or message on DIC
Frequent or incomplete regen cycles with elevated exhaust temps
Excessive fuel dilution in engine oil
Sulfur or burning smell from exhaust during failed regen

How to Fix

Forced active regen via Tech 2 or MDI scan tool; if clogging is severe, DPF removal and professional cleaning or replacement. Updated ECM calibration per TSB 14-06-04-003. Replacement DPF (ACDelco 84031507 or OEM equivalent) runs $800–$2,500. Extended highway driving after software update can restore function in mild cases.

Typical repair cost:$300 - $3,500

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Medium Confidence320 reportsLast reported by owners Invalid DateReviewed May 2026

Community Reported

275 owners

On the 2007-2018 GMC Sierra 3500HD, the factory water pump on 6.6L Duramax engines (LBZ, LMM, LML, L5P) is known to develop weep hole leaks and bearing failures, resulting in coolant loss and potential overheating. The plastic impeller on earlier units can also separate from the shaft, causing sudden loss of coolant circulation. GM issued TSB 07-06-02-002 addressing water pump replacement procedures for LBZ/LMM applications.

This issue also affects: Alfa Romeo Giulia, Audi A4 allroad, Audi Q5

Common Symptoms

Coolant puddle under front center of engine
Weep hole dripping coolant from water pump body
Engine overheating warning or high coolant temperature
Squealing or grinding noise from front of engine
Low coolant level warning light

How to Fix

Replace water pump assembly with updated steel impeller unit (ACDelco 251-2088 or Delphi WP10162). Flush and refill cooling system with Dex-Cool compliant coolant. Inspect thermostat and housing for related damage. Aftermarket options from Mishimoto and Aisin offer improved longevity. Repair requires serpentine belt removal; 2–4 hours labor.

Typical repair cost:$400 - $1,200

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Medium Confidence275 reportsLast reported by owners Invalid DateReviewed May 2026

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160 owners

On the 2015-2023 GMC Sierra 3500HD, sierra 3500HD owners towing heavy loads report intermittent trailer brake output loss, warning messages, or erratic gain behavior from the integrated trailer brake controller. NHTSA complaints and GM service bulletins/diagnostics commonly point to module/software issues, poor connector pin fit/corrosion at the 7-way, or wiring faults that cause the system to disable trailer brakes unexpectedly.

This issue also affects: Ford Transit, Audi Q5 Sportback, Dodge Magnum

Common Symptoms

"Service Trailer Brake System" message
No trailer brake output or intermittent braking
Trailer brakes grab or pulse unexpectedly
Gain setting changes but braking force does not
Trailer disconnected message with trailer connected

How to Fix

Inspect and clean the 7-way connector, check for spread pins/corrosion, and verify trailer wiring integrity. Scan for trailer brake control module DTCs and apply GM software updates/reprogramming when applicable; replace the trailer brake control module if it fails self-tests. Confirm proper ground paths and repair chassis/connector grounds as needed.

Typical repair cost:$80 - $900

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On the 2015-2024 GMC Sierra 3500HD, the Bosch piezoelectric fuel injectors on the Duramax L5P and LML engines can fail due to contaminated fuel, high-mileage wear, or internal electrical faults. A failed injector causes white smoke on startup, rough idle, misfires on the affected cylinder, and fuel dilution of the engine oil. The high fuel rail pressures (up to 36,000 PSI on the L5P) stress the injectors over time. Contaminated fuel from bulk diesel stations accelerates injector wear.

This issue also affects: Dacia Sandero, Chevrolet Silverado 2500HD, Ford Transit

Common Symptoms

White or gray smoke on cold start
Rough idle or misfire on one or more cylinders
Fuel smell in engine oil (fuel dilution)
Check engine light with injector circuit codes
Reduced power and poor fuel economy
Hard starting in cold weather

How to Fix

Diagnose the failed injector with a relative compression test and injector balance rate scan using a Tech 2 or equivalent scan tool. Replace the failed injector(s) — OEM Bosch injectors are $300-$500 each, and labor is 2-4 hours per injector ($300-$600). Always replace the injector hold-down clamp and fuel return line seals. If one injector fails at high mileage, consider replacing all 8 as the others are likely near end of life. Use a quality fuel additive like Stanadyne or Hot Shot Secret to protect remaining injectors.

What Owners Are Using

Parts and tips from 0+ owners who fixed this issue

TipAlways run a fuel additive in every tank of diesel. Stanadyne Performance Formula or Hot Shot Secret Diesel Extreme protect injectors from contaminated fuel and add lubricity.
NoteIf your oil level is rising and smells like diesel, you have a leaking injector dumping fuel into the crankcase. Do not drive — fuel-diluted oil provides almost no lubrication and will destroy bearings.
UpgradeBosch fuel injector set — OEM replacement for precise fuel delivery (Bosch Fuel Injector)
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UpgradeChevron Techron fuel injector cleaner — restores injector flow (Chevron Techron Fuel Injector Cleaner)
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Typical repair cost:$600 - $5,000

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On the 2015-2024 GMC Sierra 3500HD, the rear leaf spring packs on the Sierra 3500HD are prone to breaking or cracking under sustained heavy loads, particularly when used for frequent towing, hauling, or with fifth-wheel hitches. The main leaf or secondary leaves fracture at the spring eye or center bolt area. Broken springs cause the truck to sag on one side, produce clunking noises over bumps, and can damage brake lines or fuel lines if a broken leaf shifts.

Common Symptoms

Truck sagging on one side when loaded
Clunking or banging noise from rear over bumps
Visible crack or break in leaf spring
Rear axle shifted to one side
Uneven tire wear on rear axle
Poor ride quality and excessive bouncing when empty

How to Fix

Replace the broken leaf spring pack — OEM replacement packs run $300-$600 per side plus 2-4 hours labor. For trucks that regularly tow or haul near capacity, upgrade to heavy-duty aftermarket leaf springs from Deaver or National Spring ($500-$900 per side) or add supplemental air bags ($200-$500) to reduce spring stress. Torque the U-bolts to spec and inspect spring bushings during replacement. Consider adding a helper spring or overload spring for frequent heavy towing.

What Owners Are Using

Parts and tips from 0+ owners who fixed this issue

NoteA broken leaf spring can shift and sever brake lines or puncture fuel lines. If you hear a loud clunk from the rear and the truck sags, stop and inspect immediately.
UpgradeFirestone Ride-Rite air bags are an affordable helper that takes stress off the leaf springs when loaded. They install inside the existing coils and adjust with a simple air valve. (Firestone Ride-Rite Air Spring Kit)
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Typical repair cost:$400 - $1,500

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220 owners

On the 2007-2022 GMC Sierra 3500HD, the front axle disconnect actuator (also called the front axle engagement actuator or IWE—Integrated Wheel End) on four-wheel-drive Sierra 3500HD models is known to fail, preventing proper engagement or disengagement of 4WD. Owners report grinding noises from the front axle area in 2WD mode due to hubs failing to fully disengage, or the inability to engage 4WD when needed. Vacuum leaks in the actuator system are the most common root cause.

This issue also affects: Ford Transit, Dodge Magnum, Cadillac Escalade ESV

Common Symptoms

Grinding or humming noise from front axle area in 2WD
4WD fails to engage or disengages unexpectedly
Service 4WD warning message on instrument cluster
Front axle vibration at highway speeds
Four-wheel-drive selector switch unresponsive

How to Fix

Replace front axle actuator/IWE assembly (ACDelco 84394306 or Dorman 600-120). Inspect vacuum lines for cracks or disconnections; replace any degraded vacuum hose. On newer electric actuator-equipped models (2020+), reprogram or replace the actuator module. GM TSB 14-04-20-001 addresses 4WD engagement concerns on 2014–2019 models. Labor 1–3 hours depending on configuration.

Typical repair cost:$150 - $800

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Medium Confidence220 reportsLast reported by owners Invalid DateReviewed May 2026

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75 owners

On the 2011-2019 GMC Sierra 3500HD, owners report gear oil leaks at the rear differential pinion seal, sometimes after towing or sustained highway speeds. NHTSA complaints and owner reports describe oil slinging onto the underbody and a developing howl if fluid level drops. The issue is commonly associated with seal wear, yoke surface wear, or excessive pinion angle/driveline vibration.

This issue also affects: Audi A4 allroad

Common Symptoms

Gear oil leak at pinion/yoke area
Oil spray on spare tire/underbody
Rear differential howl/whine at speed
Burning gear oil smell after towing
Low differential fluid level

How to Fix

Confirm leak source (pinion seal vs cover vs axle seals) and check vent operation. Replace the pinion seal and inspect/replace the yoke if grooved; refill with the correct gear oil and additive requirements per axle RPO. If noise persists, inspect bearings and gear pattern for damage from low fluid.

Typical repair cost:$250 - $1,200

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Medium Confidence75 reportsLast reported by owners Invalid DateReviewed Apr 2026

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210 owners

On the 2014-2019 GMC Sierra 3500HD, owners commonly report the A/C stops cooling due to refrigerant leaks at the condenser, often from corrosion, stone impacts, or seam leaks. NHTSA complaints and owner forums frequently describe repeated recharges that only temporarily restore cooling. The issue is most often reported on 2014–2019 trucks but also appears on other years depending on condenser design.

This issue also affects: Chrysler 200, Ford Transit Connect, Ford Transit

Common Symptoms

A/C blows warm or intermittently cool air
Hissing near condenser area after shutdown
Low refrigerant pressure readings
Oily residue on condenser fins or end tanks
Cooling improves briefly after recharge

How to Fix

Confirm leak with dye or electronic leak detection and replace the A/C condenser; replace O-rings at line connections and evacuate/recharge to spec. Inspect for debris damage and consider adding a grille screen if operating in gravel/road-debris environments. Replace the receiver/drier if required by GM procedure for the model year.

Typical repair cost:$450 - $1,400

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260 owners

On the 2007-2019 GMC Sierra 3500HD, sierra 3500HD owners report clicking/ticking behind the dash and inability to control cabin temperature due to HVAC blend door or mode door actuator failures. GM service bulletins and owner reports describe stripped actuator gears or actuator motor failures that can leave the truck stuck on hot, cold, defrost, or a single vent mode.

This issue also affects: Chevrolet Equinox, Chevrolet Malibu, Chevrolet Silverado 1500

Common Symptoms

Clicking/ticking from dash when starting truck or changing temp
Stuck on hot or stuck on cold air
Air only comes from defrost or only from vents
Inconsistent temperature left-to-right (dual zone)
HVAC settings change but airflow/temperature does not

How to Fix

Identify the failed actuator (temperature blend, mode, or recirculation) using HVAC actuator recalibration and scan tool data where available. Replace the specific actuator and perform HVAC recalibration procedure after installation. If doors bind, inspect HVAC case/door movement before installing a new actuator.

Typical repair cost:$180 - $650

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Medium Confidence260 reportsLast reported by owners Invalid DateReviewed Apr 2026

On the 2015-2024 GMC Sierra 3500HD, the recirculating ball steering gear box on the Sierra 3500HD develops fluid leaks at the input shaft seal and sector shaft seal, leading to power steering fluid loss and increased steering play. The heavy-duty application and large tires accelerate wear on the steering box internals. Owners report the steering develops excessive play (1-2 inches at the wheel) and a wandering feeling on the highway, especially when towing.

This issue also affects: Chevrolet Malibu, Chevrolet Uplander, Chevrolet Cobalt

Common Symptoms

Power steering fluid leaking from steering gear box area
Excessive steering wheel play (more than 1 inch)
Wandering on highway requiring constant correction
Groaning or whining from steering when turning
Low power steering fluid warnings
Loose or vague steering feel especially when towing

How to Fix

For minor leaks, replace the seals ($50-$100 parts, $300-$500 labor) as a temporary fix. For excessive play, the steering gear box needs replacement with a remanufactured or new unit ($400-$900 for the box). A Borgeson steering box upgrade ($500-$700) is a popular heavy-duty replacement that provides tighter steering and better durability. Always replace the Pitman arm and check tie rod ends during the job. A full front-end alignment is required afterward.

What Owners Are Using

Parts and tips from 0+ owners who fixed this issue

UpgradeThe Borgeson heavy-duty steering box is the go-to upgrade for 3500HD owners. It is a direct bolt-in replacement with tighter tolerances and better seals than the factory unit. (Borgeson Heavy Duty Steering Box)
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TipCheck power steering fluid monthly. Catching a leak early prevents air from entering the system, which causes pump damage and much more expensive repairs.

Typical repair cost:$400 - $1,500

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On the 2015-2024 GMC Sierra 3500HD, the cast iron exhaust manifolds on the Duramax diesel engine are prone to cracking and warping due to extreme exhaust gas temperatures and thermal cycling. Cracks typically develop at the manifold-to-head mounting points, causing exhaust leaks that produce a ticking noise on cold starts. The up-pipe connections also warp, allowing soot to blow onto engine components. This issue affects both the LML (2015-2016) and L5P (2017-2024) engines.

This issue also affects: Chevrolet Silverado 2500HD, Audi Q7, Citroën Berlingo

Common Symptoms

Ticking or tapping noise on cold start that fades as engine warms
Exhaust smell in cab especially at idle
Soot buildup on engine components near manifold
Visible cracks in exhaust manifold on inspection
Slightly reduced fuel efficiency
Exhaust leak sound under load

How to Fix

Replace the cracked exhaust manifold with OEM or upgraded aftermarket units ($400-$800 per side for parts). PPE and Pacific Performance Engineering make reinforced stainless steel manifolds ($600-$1,200) that resist cracking. New exhaust manifold bolts and gaskets are essential during replacement — always use OEM bolts as they are designed for the thermal expansion. Labor runs 4-8 hours ($600-$1,200) depending on which side. Inspect up-pipes for warping at the same time.

What Owners Are Using

Parts and tips from 0+ owners who fixed this issue

TipLet the truck idle for 30-60 seconds before driving in cold weather. Rapid thermal shock from cold-starting and immediately driving under load accelerates manifold cracking.
NoteDo not ignore exhaust manifold leaks — they can damage the turbo housing and warp the cylinder head over time. Fix it before it becomes a $5,000+ problem.
UpgradeDorman exhaust manifold — solves cracking issues on many models (Dorman Exhaust Manifold)
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UpgradeDorman exhaust manifold bolt and stud kit (Dorman Exhaust Manifold Hardware Kit)
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Typical repair cost:$800 - $2,500

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On the 2015-2020 GMC Sierra 3500HD, the instrument cluster in 2015-2020 Sierra 3500HD trucks suffers from LCD pixel failure, causing portions of the Driver Information Center (DIC) display to become unreadable. Individual pixels or entire segments go blank, making it impossible to read trip computer data, gear indicator, or warning messages. The issue is caused by solder joint failure on the cluster circuit board from thermal cycling and vibration. The speedometer and tachometer gauges may also develop stepper motor failures, causing inaccurate or stuck readings.

This issue also affects: Audi Q5 Sportback, Audi A4, Audi A6

Common Symptoms

Missing pixels or blank segments on dashboard display
DIC screen partially or fully blank
Gear indicator not showing current gear
Speedometer or tachometer reading incorrectly
Gauges sticking or not returning to zero when off
Intermittent display flickering

How to Fix

The cluster can be sent to a repair service specializing in GM instrument clusters ($150-$300) for re-soldering and stepper motor replacement — this fixes 90% of cases. A new OEM cluster from the dealer costs $500-$1,000 and requires VIN programming. Aftermarket rebuilt clusters are available for $200-$400. Some owners have successfully repaired the solder joints themselves with a soldering iron, but this requires electronics experience. The cluster must be programmed to the truck VIN after replacement.

What Owners Are Using

Parts and tips from 0+ owners who fixed this issue

TipBefore buying a new cluster, try a cluster repair service. Companies like Dr. Speedometer and Tanin Auto Electronix repair these for $150-$250 with a lifetime warranty. Much cheaper than dealer replacement.
UpgradeProfessional OBD-II diagnostic scanner for reading infotainment and body module codes (BlueDriver Bluetooth Pro OBD2 Scan Tool)
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Typical repair cost:$150 - $1,000

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Frequently Asked Questions

What are the most common GMC Sierra 3500HD problems?

According to Au7o's analysis of 3,560+ owner reports, the 2015-2015 GMC Sierra 3500HD has 21 documented issues. The most frequently reported are: CP4.2 High-Pressure Fuel Pump Catastrophic Failure, DPF (Diesel Particulate Filter) Clogging and Regeneration Failure, Turbocharger VGT Vane Sticking and Boost Control Failure (Duramax LML/L5P). Of these, 8 are rated critical and should be addressed promptly.

Is the GMC Sierra 3500HD reliable?

The 2015-2015 GMC Sierra 3500HD has 21 known issues documented across 3,560+ owner reports. 8 issues are rated critical: CP4.2 High-Pressure Fuel Pump Catastrophic Failure and DPF (Diesel Particulate Filter) Clogging and Regeneration Failure and Turbocharger VGT Vane Sticking and Boost Control Failure (Duramax LML/L5P) and Duramax Water Pump Failure and Coolant Leak and Trailer brake controller / integrated trailer brake module malfunction and Allison 1000 Transmission Control Module and Sensor Failures and Diesel Injector Failure Causing White Smoke and Rough Running and Rear Leaf Spring Breakage Under Heavy Loads. 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.

How much does it cost to fix common GMC Sierra 3500HD problems?

Repair costs for known GMC Sierra 3500HD issues range from $80 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 $10,000-$18,000 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 2008-2016 GMC Sierra 3500HD EGR Cooler Failure and Coolant Contamination (Duramax LMM/LML)?

The exhaust gas recirculation cooler on 6.6L Duramax LMM and LML engines is prone to internal cracking, allowing coolant to enter the EGR system and combustion chamber. Owners experience white steam from the exhaust, unexplained coolant loss, and in severe cases hydrolocking. Thi… Repairs typically run $900-$2,800. Severity: critical.

All 21 Known Issues

When Issues Typically Appear

2011-2020 GMC Sierra 3500HD: CP4.2 High-Pressure Fuel Pump Catastrophic Failure#

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2011-2022 GMC Sierra 3500HD: Turbocharger VGT Vane Sticking and Boost Control Failure (Duramax LML/L5P)#

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2007-2019 GMC Sierra 3500HD: Glow plug control module / glow plug circuit faults causing hard cold starts (Duramax)#

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2011-2020 GMC Sierra 3500HD: Diesel Exhaust Fluid (DEF) System Failures#

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2008-2019 GMC Sierra 3500HD: Allison 1000 Transmission Control Module and Sensor Failures#

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2007-2020 GMC Sierra 3500HD: Allison 1000/2000 Series Transmission Torque Converter Shudder#

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2011-2022 GMC Sierra 3500HD: DPF (Diesel Particulate Filter) Clogging and Regeneration Failure#

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2007-2018 GMC Sierra 3500HD: Duramax Water Pump Failure and Coolant Leak#

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2015-2023 GMC Sierra 3500HD: Trailer brake controller / integrated trailer brake module malfunction#

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2015-2024 GMC Sierra 3500HD: Diesel Injector Failure Causing White Smoke and Rough Running#

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2015-2024 GMC Sierra 3500HD: Rear Leaf Spring Breakage Under Heavy Loads#

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2007-2022 GMC Sierra 3500HD: Front Differential Actuator Failure Causing 4WD Engagement Problems#

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2011-2019 GMC Sierra 3500HD: Rear axle pinion seal leak and differential fluid loss (AAM 11.5/11.8)#

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2014-2019 GMC Sierra 3500HD: A/C condenser leak leading to loss of refrigerant and warm air#

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2007-2019 GMC Sierra 3500HD: Blend door actuator failure causing temperature/airflow control problems#

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2015-2024 GMC Sierra 3500HD: Steering Gear Box Leak and Excessive Play#

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2015-2024 GMC Sierra 3500HD: Exhaust Manifold Cracking and Warping (Duramax L5P/LML)#

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2015-2020 GMC Sierra 3500HD: Dashboard Instrument Cluster Pixel and Display Failure#

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