2015 Chevrolet Silverado 3500

From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.

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 ID

11751378

Incident

Jul 14, 2026

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 ID

11751129

Incident

Jun 1, 2026

The 2nd stage of this truck was not completed and the title was done in fraud in 2015 by Jon Hall Chevy in Daytona. I need this inspected as it shouldn't be on the road. Only 1 MCO without water Marks on it. this is a 2 stage truck should have 2. but nope only one we are getting the run around.

NHTSA ID

11718995

Incident

Jul 10, 2024

Catastrophic failure of the CP4 fuel pump

NHTSA ID

11698006

Incident

Oct 9, 2024

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 ID

11697982

Incident

Sep 8, 2025

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 ID

11666246

Incident

Jun 9, 2025

Mileage

270,000 mi

A rear defrost system malfunctioned and was smoking in the interior of the vehicle followed by the rear glass shattering. The electrical malfunction could have easily started a fire and glass flying around the cab a highway speeds could definitely be hazard. I called the dealership and they were unconcerned and gave me a quote to replace it. the dealer or the aftermarket glass replacement company have not heard of it happening. I did find a recall in Canada. Strangely enough mine was done in Canada and it happened again.

NHTSA ID

11652076

Incident

Apr 1, 2025

The contact owns a 2015 Chevrolet Silverado 3500. The contact stated that while the vehicle was parked, the contact noticed that the instrument panel was inoperable. The contact stated that the instrument panel failed to function properly while attempting to activate the windshield wiper. The vehicle was taken to the dealer, where it was diagnosed that the fuse block had failed and needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The approximate failure mileage was 5,100.

NHTSA ID

11647041

Incident

Mar 7, 2025

Mileage

5,100 mi

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