GMC Sierra 3500HD Problems: 16 Issues Every Owner Should Know
2007-2024 model years Β· 1,600+ owner reports Β· Updated April 2026
According to Au7o's analysis of 1,600+ owner reports, the 2007-2024 GMC Sierra 3500HD has 16 documented known issues, with 7 rated critical. The most serious are CP4.2 High-Pressure Fuel Pump Catastrophic Failure ($10,000-$18,000 repair), Trailer brake controller / integrated trailer brake module malfunction ($80-$900 repair), Transfer case pump rub causing fluid leak and transfer case damage (4WD) ($450-$2,800 repair), Electric power steering (EPS) assist loss / reduced assist warnings (new body style), 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. DIY maintenance guides at au7o.io.