2015 Chevrolet Silverado 3500 Fuel system Problems

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

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

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.

NHTSA ID

11590505

Incident

Feb 22, 2024

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.

NHTSA ID

11588240

Incident

Feb 22, 2024

The contact owns a 2015 Chevrolet Silverado 3500. The contact stated while driving approximately 35 MPH, the check engine warning light illuminated. The contact had taken the vehicle to an independent mechanic where it was diagnosed and determined that the High-Pressure Fuel Pump (HPFP) needed to be replaced. The vehicle had not been repaired. The contact was advised that the HPFP were on national back order. The manufacturer had been informed of the failure. The contact researched online and related the failure to NHTSA Campaign Number: 21E101000 (Fuel System, Diesel). The failure mileage was approximately 150,000.

NHTSA ID

11518893

Incident

Apr 22, 2023

Mileage

150,000 mi

TL* THE CONTACT OWNS A 2015 CHEVROLET SILVERADO 3500. THE CONTACT STATED WHILE PARKED, THE HIGH-PRESSURE FUEL PUMP FAILED WITHOUT WARNING. THE CONTACT STATED HE HEARD AN ABNORMAL NOISE AND TURNED OFF AND RESTARTED THE VEHICLE HOWEVER, THE VEHICLE SHUTOFF WITHOUT WARNING. THE CONTACT HAD THE VEHICLE TOWED TO WOODLAND CHEVROLET (530 QUALITY CIR, WOODLAND, CA 95776) WHERE THE VEHICLE WAS DIAGNOSED WITH A HIGH-PRESSURE FUEL PUMP FAILURE. THE VEHICLE REMAINED AT THE DEALER UNREPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND A CASE WAS FILED. THE FAILURE MILEAGE WAS 180,000.

NHTSA ID

11355336

Incident

Sep 4, 2020

Mileage

180,000 mi

CP4 FUEL PUMP FAILURE AND ENGINE FAILURE- STARTED TRUCK THAT MORNING, 5 MIN LATER IT SHUT OFF AND HASN'T STARTED AGAIN. HUB EXPLODED MAKING 4WHEEL DRIVE IMPOSSIBLE WHEN DRIVING DOWN HEY. AC BLENDER STOPPED WORKING AC VENTS BLOW HOT AIR ON RIGHT SIDE OF DASH WHILE IN MOTION.

NHTSA ID

11353898

Incident

Sep 7, 2020

Mileage

96,000 mi

TL* 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.

NHTSA ID

11322410

Incident

Apr 17, 2020

Mileage

114,000 mi

I NEVER RECEIVED A RECALL ON MY CHEVROLET TRUCK WHICH IS THE SAME YEAR MAKE AND MODEL AS THIS ONE. TOOK IT TO A DEALERSHIP AND HAD IT FIXED. THEY SAID IT WASN'T RECALLED SO WE HAD TO PAY THE BILL. ISN'T THEIR A WAY TO FIND THE RECALL AND GET REIMBURSED FOR THE REPAIR BILL AND ALL THE ASSOCIATED COSTS? WE HAVE CALLED AND MADE A COMPLAINT TO NHTSA. NOTHING CAME OF IT. IT STILL IS A SAFETY DEFECT THAT SHOULD BE REPAIRED WITH NO COST TO THE CUSTOMERS.

NHTSA ID

11298635

Incident

Jan 1, 2015

TL* THE CONTACT OWNS A 2015 CHEVROLET SILVERADO 3500. WHILE TOWING A HORSE TRAILER AND DRIVING APPROXIMATELY 55 MPH, THE VEHICLE SUDDENLY STALLED. THE VEHICLE WAS TOWED TO THE LOCAL DEALER (BACHMAN-BERNARD CHEVROLET BUICK GMC, 3365 E. ANDREW JOHNSON HWY, GREENEVILLE, TN) WHERE IT WAS 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.

NHTSA ID

11110687

Incident

Jul 6, 2018

Mileage

33,922 mi

MY CHEVY SILVERADO 3500 DURAMAX DIESEL TRUCK HAD AROUND 52,000 MILES ON THE ODOMETER & WAS STATIONARY WHEN THE FUEL INJECTION CHECK BALL EXPLODED (ACCORDING TO THE DEALERSHIP) & CAUSED THE ENGINE TO STOP & BECOME IMMOBILE. THE TRUCK WAS TOWED TO THE NEAREST DEALERSHIP & REPAIRED @ AROUND $12,000 WORTH OF DAMAGE. WARRANTY COVERED IT @ 100% & THE VEHICLE IS BACK RUNNING. I LIVE IN A FARMING/RANCHING PART OF THE USA WHERE MULTIPLE PEOPLE DRIVE DIESEL PICKUPS. I HAVE TALKED TO MULTIPLE PEOPLE WHO HAVE HAD THE EXACT SAME PROBLEM WITH THEIR CHEVY DURAMAX TRUCKS (ACCORDING TO THEIR DEALERSHIP). WHEN THIS CONDITION OCCURRED ON THEIR VEHICLES, THEY WERE DRIVING & THE VEHICLE BECAME IMMOBILE. THIS CONCERNS ME BECAUSE WHEN THE ENGINE STOPS WHEN DRIVING YOU COULD LOSE POWER STEERING/FULL BRAKING ABILITY. I HAVE A FAMILY AS WELL AS OTHERS, I DO NOT KNOW OF ANY DEATHS RELATED TO THIS ISSUE, BUT NO ENGINE POWER COULD RESULT IN LOSS OF POWER STEERING/FULL BRAKING ABILITY, RESULTING IN EQUIPMENT/BODILY INJURY. I CONTACTED CHEVY CUSTOMER SUPPORT & SUBMITTED A CLAIM, THEY SAID THEY WOULD SUBMIT THE CLAIM TO THE RECALL DEPARTMENT. CHEVY ALSO CONTACTED THE DEALERSHIP & SPOKE WITH THE SERVICE GUY TO CONFIRM MY CLAIM, HE SAID HE CONFIRMED THE MULTIPLE OCCURRENCES THAT THEY HAVE SEEN. AS A MATTER OF A FACT, ANOTHER CHEVY DURAMAX WAS TOWED TO THE DEALERSHIP WITH THE EXACT ISSUE, WHILE MY TRUCK WAS BEING REPAIRED. THE DEALERSHIP CONFIRMED THAT CHEVY HAS NOT FIXED THE ISSUE WITH THE FUEL INJECTION SYSTEM, SO THE REPAIRS WERE MADE WITH THE EXACT SAME FAULTY (NEW PARTS), ACCORDING TO THE DEALERSHIP. WHEN SEARCHING FOR THIS ISSUE ON THE WEB, MULTIPLE OF THE SAME OCCURRENCES ARE LISTED. IN MY OPINION THIS ISSUE NEEDS TO BE EVALUATED WITH A CORRECTIVE ACTION PUT IN PLACE TO PREVENT FURTHER INCIDENTS SIMILAR TO THIS FROM HAPPENING.

NHTSA ID

10995037

Incident

Apr 20, 2017

Mileage

52,000 mi

P2636 TRANSFER PUMP INSUFFICIENT FLOW - VEHICLE STALLED WHILE DRIVING, UNABLE TO RESTART. TOWED INTO DEALERSHIP TO FIND TRANSFER PUMP WHICH TRANSFERS FUEL FROM REAR TO FRONT TANK HAD FAILED. VEHICLE HAS 37,880 MILES AT TIME OF INCIDENT. BELIEVE THIS TO BE RECURRING ISSUE, WHICH SHOULD BE ADDRESSED WITH MANUFACTURER.

NHTSA ID

10966548

Incident

Feb 28, 2017

Mileage

37,880 mi

BOUGHT THIS VEHICLE NEW FROM DEALER IN SEPT 2015 WITH THE DEALER INSTALLED FLATBED ALREADY ON IT, ON THEIR DEALERSHIP LOT. FUEL MILEAGE WAS POOR FROM THE FIRST, "ENGINE LIGHT ON" FROM THE FIRST; TRANSMISSION DRAGGING FROM THE FIRST DAY WE BOUGHT IT. SERVICE ADVISORS AND THE SALESMAN SAID DRIVE IT AND IT WILL CLEAR OUT. IT GOT WORSE. THE DEALERSHIP FINALLY SENT IT TO THE COMPANY WHO INSTALLED THE FLATBED FOR THEM, AND THEY SAID THERE WAS AN ELECTRICAL SHORT IN THE FUEL PUMP WHICH THEY REPLACED. THE AUTOMATIC TRANSMISSION DID NOT SHIFT SMOOTHLY WHEN WE GOT IT BACK, AND THE DEALERSHIP SAID "IT PERFORMS AS DESIGNED". BUT, THIS IS AN AUTOMATIC 6 SPEED CHEVROLET TRANSMISSION IN A 2015 CHEVROLET 3500 SILVERADO WITH A 6.0 GASOLINE ENGINE. THE TRANSMISSION DRAGS FROM 5TH GEAR AND THEN DRAGS IN 6TH GEAR. I HAVE TO LET OFF THE GAS PEDAL FOR THE TRANSMISSION TO SHIFT. IF I LET IT DRAG OUT, IT USES FUEL AND SOUNDS LIKE I AM STUCK IN GEAR. WE HAVE TAKEN IT TO 3 DIFFERENT CHEVROLET DEALERSHIPS, AND THEY SAY SOMETHING IS WRONG BUT WE CAN'T TAKE IT APART TO FIX IT. THE SERVICE MANAGER SAID FOR ME TO DRIVE IT UNTIL THE TRANSMISSION "BLOWS UP BECAUSE IT IS UNDER WARRANTY". I TOOK IT TO A RELIABLE TRANSMISSION SHOP, BUT THEY WON'T TOUCH IT BECAUSE IT IS UNDER WARRANTY, BUT THEY SAID THAT THERE IS SOMETHING WRONG THAT IT DOES NOT SHIFT SMOOTHLY INTO ALL 6 GEARS. IT ONLY HAS 3600 MILES. WE HAVE TO DRIVE IT ONCE A WEEK TO KEEP THE BATTERY CHARGED. I DON'T PULL OR HAUL ANYTHING WITH IT. THIS IS HAPPENING BOTH IN CITY DRIVING AND HIGHWAY DRIVING.

NHTSA ID

10860076

Incident

Sep 28, 2015