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Chevrolet Silverado 2500 HD Problems

RepairPal has identified the most common problems with the Chevrolet Silverado 2500 HD based on complaints from actual vehicle owners. We'll tell you what the problem is and what it'll take to fix it.

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34
Known Problems

Illumination of the Check Engine Light can be caused by a loose or worn gas cap.

It is common for the fuel level sensor in the fuel tank read the fuel level incorrectly. The sensor must be replaced to correct the condition. Our technicians recommend having the complete fuel pump module replaced on high mileage vehicles.

One or both secondary air injection check valves may become restricted causing poor air flow resulting in illumination of the Check Engine Light. It is often recommend to replace both check valves even if a fault code is set for only one bank of cylinders. Replacing only one valve may result in a return trip to the repair shop.

The inside door handles are prone to breaking.

The speedometer or other instrument panel gauge may begin to work erratically at times. Our technicians tell us that the instrument cluster must be sent to a repair facility to correct this fault. The warranty has been extended on some of these units to 7 years or 70,000 miles.

A poor electrical ground under the battery tray may cause the ABS warning light to illuminate. Our technicians tell us that cleaning and properly securing this ground and also the main ABS ground on the frame rail below the drivers door may be necessary.

The 2004-2007 Chevrolet Silverado 2500HD has known issues with the EVAP system, a part of your emission control system.

The EVAP canister vent valve or valve solenoid wiring may fail causing illumination of the check engine light, setting code P0446, and problems filling the tank with fuel.

To correct the issue, the EVAP canister vent valve, solenoid, and wiring must be inspected. The most common fix is replacement of the wiring connector or replacement of the vent valve assembly.

The 4WD transfer case encoder motor position sensor or the selector switch may fail causing the service 4WD message to be displayed. Fault code(s) stored in the transfer case control module will be of assistance in determining the exact fault causing the message to be displayed.

The CD player may fail due to an internal fault with the radio. Our technicians tell us that in most cases, the radio unit will need to be sent to a specialty repair shop to correct this issue.

The 2001-2002 Chevrolet Silverado 2500HD has a known issue with the air pump check valve which causes illumination of the check engine light. There are no notable symptoms, but the vehicle will not pass state inspection or smog testing. 

When the valve fails, it sticks closed, and the computer sets the code P1416. Replacement of the check valve is the only fix, as the valve is not serviceable. 

This page can provide more information about the air pump check valve. 

The muffler heat shield may become loose on the muffler causing a rattle or popping noise. Our technicians tell us there is a kit available from GM to correct this problem.

The throttle position sensor (TPS) on the Chevrolet Silverado 2500 HD is notorious for failure which causes:

This issue is related to the throttle position sensor, and can be caused by faulty wiring to the TPS, bad connection at the TPS, or a failed TPS.

To correct this issue, the wiring harness, connector, and throttle position sensor must be inspected, tested, and/or replaced. The most common cause is a faulty TPS.

One or more heater & AC (HVAC) air delivery and/or temperature mode door actuator may fail. This can result in incorrect air delivery or temperature. If this occurs, fault code(s) stored in the HVAC control module should be available to assist with diagnoses.

A loose or worn gas cap could be cause the Check Engine Light to illuminate.