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severe 39 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
If the damper comes loose, a fuel leak may result. Fuel leakage, in the presence of an ignition source, could result in a fire.
The manufacturer has issued service bulletins covering engine on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
This informational bulletin provides information on close coupled converters and there affect on newly installed engines or engines during there break in period.
full bulletin at NHTSA ↗This informational bulletin provides information to technicians regarding intake manifold inspection/replacement after severe internal engine damage.
full bulletin at NHTSA ↗This technical bulletin provides repair information for repairing the IP to body harness connector to correct a customer concern for intermittent Malfunction Indicator Lamp (MIL) illuminated with Reduced Engine Power displayed and DTC P2138 set.
full bulletin at NHTSA ↗This informational bulletin provides information to technicians regarding intake manifold inspection/replacement after severe internal engine damage.
full bulletin at NHTSA ↗GMC/CHEVROLET: ENGINES, WITH EGR SYSTEM, HAS LEAKAGE FROM EGR COOLER ENGINE COOLANT INTO THE COMBUSTION CHAMBER. MODEL 2002-15 SILVERADO, SIERRA, 2004-09 KODIAK C4500-C5500, TOPKICK C4500-C5500, 2006-15 EXPRESS, SAVANA.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The 2006 Silverado engine shows multiple recurring failure patterns across these 39 complaints.
Broken exhaust manifold bolts dominate reports: bolt heads fracture or shear off, starting around 40,000 miles, mostly on the driver side. Cold-start ticking is the hallmark sign. Owners note this is widespread across the 1999–2007 Silverado/Sierra generation (estimated 80–90% of trucks in those years). Broken bolts allow exhaust and carbon monoxide into the cabin and cause emissions test failures. Dealer repair quotes run $2,100 or more. Multiple owners state GM is aware but has not recalled the defective bolts.
Cam rocker arm roller bearing failure appears on 5.3L V8 engines around 105,000–116,000 miles, producing loud engine knock. Repair or rebuild bills range from $3,200 to $6,000. Owners report GM acknowledges the defect on 2005–2007 5.3L engines but refuses recalls or reimbursement, claiming engines "basically do not last over 115,000 miles."
Reduced engine power / limp mode strikes without warning at highway speeds. One owner's truck dropped to 10 mph while traffic approached at 60+ mph; dealership replaced emissions parts, wiring, throttle body, and harness, yet failures recurred within days to weeks. This pattern repeats across multiple complaints.
Blower motor resistor failure melts wiring and creates fire hazard while disabling defrost. One owner reported the same failure on two other Silverados (2004–2005) at their workplace. Chevy issued a service bulletin but no recall.
Engine fires are reported in three narratives: one after repeated overheating repairs, one seven hours after driving, and one at idle in a parked vehicle. Vehicles were totaled.
Other frequent complaints include turbocharger vane stiction (Duramax), transmission cooler line leaks, excessive oil consumption, knock sensor corrosion, and severe rust on undercarriages despite low mileage and careful maintenance.
Same Chevrolet Silverado engine reports on nearby years: 2005 · 2007 · 2008 · 2009
Engine enters severe power-limiting limp mode with 'Reduced Engine Power' warning, dropping vehicle speed to ~10 mph without operator control. Multiple owners report repeated failures even after dealer repair attempts (emissions parts, wiring harness replacement, throttle body work, solder repairs). Poses immediate highway safety risk.
When: 2006-2011; recurring within days/weeks of repair
Symptoms owners cite: Check engine light illuminates; Dashboard 'Reduced Engine Power' warning; Truck speed drops to ~10 mph automatically; No response to accelerator pedal; Recurs repeatedly despite multiple dealer visits
Codes mentioned: Check Engine Light (specific codes not stated)
Repairs/costs cited: Dealer tried: emissions part replacement ($400), loose wire diagnosis, solder of connections, wiring harness replacement, throttle body replacement. Repairs were temporary; failures recurred.
Exhaust manifold bolts fracture or shear off, most commonly on driver side, creating exhaust leaks. Occurs as early as 40,000 miles. Causes cold-start ticking noise, exhaust odor in cabin, carbon monoxide intrusion, and potential emissions test failure. Owner narratives and mechanics note this is widespread across 1999–2007 Silverados and Sierras (estimated 80–90% of affected years). Multiple owners cite dealer refusal to repair under warranty or knowledge of the defect.
When: 40,000–116,000 miles; cold-start ticking decreases with warm engine
Symptoms owners cite: Ticking or clicking noise when engine cold; Exhaust smell inside cabin; Exhaust odor under hood; One or more bolt heads missing visibly; Carbon monoxide in passenger compartment; Vehicle fails emissions test
Codes mentioned: Check Engine Light (emissions-related)
Repairs/costs cited: Repairs cited: bolt replacement, manifold re-gasket work. One owner quoted $2,100 for repair. Dealers note this is common.
Cam rocker arm roller bearing degrades, producing engine knock. Owner with 115,000 miles faced $3,242.84 repair bill; another owner with 60,000 miles on a used truck faced $3,500 motor rebuild estimate (camshaft, bearings, oil pump, seals, gaskets). Second owner notes GM told them engines 'basically do not last over 115,000 miles' and refused to reimburse or recall the part despite GM awareness of defect on 2005–2007 5.3L engines. A third owner's mechanic stated a new engine is cheaper than rebuilding.
When: 105,000–116,000 miles (some used vehicles earlier depending on prior miles)
Symptoms owners cite: Loud knocking/crunching noise from low end of engine; Knock/crunching from #2 lifter area; Noise under load or acceleration; absent at idle
Codes mentioned: None explicitly stated
Repairs/costs cited: Repair: rocker arm roller bearing replacement ($3,242.84 actual bill). Motor rebuild quoted at $3,500–$6,000 as alternative (cheaper than component repair in some cases).
Recalls/TSBs owners mention: GM aware of defect on 2005–2007 5.3L engines but has not recalled part. GM refused reimbursement when contacted by owner.
Rear knock sensor (Bank 1, Circuit Low Input) corrodes due to water intrusion, triggering Service Engine Soon light with code P0327. Owner replaced both sensors and wiring harness twice within 3 weeks; mechanic confirmed water-induced corrosion both times. Third code appearance suggests ongoing water ingress.
When: Timing not specified; recurrence within 1–2 weeks of repair
Symptoms owners cite: Service Engine Soon light illuminates; Code P0327 (Knock Sensor 1, Circuit Low Input, Bank 1); Corroded rear knock sensor on second inspection; Water intrusion evident
Codes mentioned: P0327
Repairs/costs cited: Replaced both knock sensors and wiring harness. Rear sensor corroded in both initial and second repair.
Turbocharger boost control vanes stick or stop moving, triggering Check Engine light with code P2563 (Turbocharger Boost Control Solenoid). First owner had turbocharger replaced under warranty ($100 deductible). Second owner experienced identical failure 28,342 miles after first repair, requiring full turbocharger replacement at $2,889.74. Narrative suggests trend of repeated failure in Duramax units.
When: Early life failures; second failure at 28,342 miles post-initial replacement
Symptoms owners cite: Check Engine light; Code P2563; Turbo vanes stick or stop moving (stuck at 69% position reported); May activate limp/derate mode under load
Codes mentioned: P2563, Turbocharger Boost Control Solenoid codes
Repairs/costs cited: First turbocharger replacement under original warranty with $100 deductible. Second replacement (new turbocharger, seals, gaskets, ECM reprogramming) cost $2,889.74.
Recalls/TSBs owners mention: First repair covered under warranty. No TSB noted for second failure in narratives.
Engine consumes oil faster than normal, requiring top-ups between service intervals. One owner with 8.1L motor (2500 HD) added 1.25 quarts at 1,800 miles since last oil change; dealer states 1–2 quarts per 2,000 miles is normal for this engine. Another owner purchased used truck and within 1.5 months of a fresh oil change, vehicle smoked profusely and required 5 quarts to restore oil level after a 6-hour highway drive, suggesting major leak or burning.
When: Early in ownership; one case within 1.5 months of purchase
Symptoms owners cite: Low oil warning light (8.1L case); Excessive oil depletion between changes; Engine smoking (second case); Need for multiple quarts to restore level
Repairs/costs cited: 8.1L owner reports dealer acknowledged 1–2 quarts per 2,000 miles as expected consumption; second owner had to add 5 quarts after smoking incident but specific repair not stated.
Recalls/TSBs owners mention: 8.1L: dealer states consumption is normal design; no recall or TSB mentioned.
Transmission fluid cooler lines (lower line and line from radiator to auxiliary cooler) leak due to faulty hose crimps on Allison transmissions. One owner with 6.6L Duramax and 59,000 miles reported both lines leaking; dealer confirmed quality defect in lines, not wear-and-tear. Fluid depletion can lead to transmission failure if unrepaired.
When: 59,000 miles reported; dealer noted lines should not fail at this mileage
Symptoms owners cite: Transmission fluid leaks from lower cooler line; Leaks from radiator-to-aux cooler line; Fluid depletion over time
Repairs/costs cited: Cooler lines replaced by dealer; dealer confirmed faulty crimp design, not normal wear.
Blower motor resistor shorts out and melts wiring harness. One owner reported burning smell and replacement; narrative notes same failure occurred on two other Silverados (2004 and 2005 models) at owner's workplace. Creates fire hazard and disables defrost function, affecting visibility and safety. Second narrative confirms sudden blower failure with melted wiring under dash and notes Chevy issued a service bulletin but no recall.
When: Earlier in vehicle life; failures on 2004, 2005, 2006 models indicate recurring issue
Symptoms owners cite: Blower motor inoperative; Burning smell from dashboard area; Melted wiring harness under dash; Loss of defrost capability; Wiring harness short (one case: dual AC control short on blower)
Repairs/costs cited: Resistor and wiring replacement (replaced twice in one case). One owner notes visible melting under dash.
Recalls/TSBs owners mention: Service bulletin issued by Chevy per one narrative; no recall.
Intermittent low fuel pressure codes and turbocharger boost control codes on stock Duramax. Owner reports codes P003A (Turbocharger Boost Control Position Not Learned) and P0087 (Low Fuel Pressure) appearing intermittently from new. Dealer repeatedly changed fuel filter and reset codes; recently truck entered limp/derate mode while towing (first drivability event noted in August 2014). As of October 2014 (94,000 miles), codes recur weekly despite filter changes and normal fuel pressure diagnostics. Dealer confirms no bulletins for issue.
When: From new; recurrence weekly as of 94,000 miles (October 2014)
Symptoms owners cite: Dash message: 'Change Fuel Filter'; Check Engine light; Code P003A (Turbocharger Boost Control Position Not Learned); Code P0087 (Low Fuel Pressure); Derate/limp mode while towing (first occurrence August 2014)
Codes mentioned: P003A, P0087
Repairs/costs cited: Fuel filter replaced multiple times; no fuel pressure issues found diagnostically.
Recalls/TSBs owners mention: Dealer states no Chevy bulletins available for this issue.
Engine fire in engine compartment. One owner reported vehicle returned to dealer 11 times for various issues between May and December 2006; starting December 2006, repeated overheating problems with parts replaced on each visit. On January 20, 2007, engine caught on fire. Second narrative: engine compartment fire 7 hours after truck was driven at 4 AM; truck totaled. Third narrative: smoke rising from hood of parked vehicle at 30,000 miles; operator lifted hood and saw flames; fire department extinguished fire; cause unknown.
When: One at 30,000 miles; one after repeated overheating repairs; one at unspecified mileage but 7 hours after use
Symptoms owners cite: Smoke visible from hood/engine compartment; Flames in engine compartment; Repeated overheating prior to fire (one case)
Repairs/costs cited: Vehicles destroyed or totaled; no repair data available.
During braking on icy road at 30–50 mph, transmission unexpectedly shifted out of gear. Check Engine light illuminated. Dealer diagnosed heater cord blocking transmission function and repaired. One additional transmission-related complaint (narrative #11) involved heater cord impact; another (narrative #24) involved heater motor running continuously and draining battery. Suggests potential design interaction between cooling and transmission systems.
When: 37,000 miles (failure); 37,400 miles (current, post-repair)
Symptoms owners cite: Transmission unexpectedly shifts out of gear during braking; Check Engine light illuminates; Occurs on icy roads during braking
Codes mentioned: Check Engine Light
Repairs/costs cited: Heater cord cleared/repaired by dealer.
Heater blower motor operates continuously even with vehicle shut off, causing battery discharge. Owner at 116,000 miles reported issue to dealer and manufacturer; both denied assistance. Vehicle was repaired but specifics not stated.
When: 116,000 miles
Symptoms owners cite: Blower motor runs constantly; Operates even with vehicle powered off; Battery drain
Repairs/costs cited: Vehicle was repaired; specific repair details not provided.
Recalls/TSBs owners mention: Dealer and manufacturer both denied assistance per narrative.
Passenger side exhaust flange gasket fails to maintain seal due to design flaw preventing adequate bolt tightening. Results in carbon monoxide and exhaust gases entering passenger compartment.
When: Normal vehicle operation; timing not specified
Symptoms owners cite: Carbon monoxide/exhaust fumes in passenger compartment; Exhaust flange leak
Repairs/costs cited: Design prevents adequate seal; no repair method stated.
Low-frequency harmonic vibration/rumble felt through floor and heard throughout cabin. Present from second week of ownership on 1500 HD Super Crew Cab. Varies with speed and load. Dealership worked on problem four times in five months without resolution; owner scheduled fifth visit. Rumble progressively worsens until vehicle is serviced.
When: From second week of ownership; unresolved across multiple service visits
Symptoms owners cite: Harmonic rumble felt through floor; Audible throughout cabin; Varies with speed and load; Progressively loudens between services
Repairs/costs cited: Four service attempts over five months with no resolution.
Right front tire began smoking and caught fire while driving on Ohio Turnpike westbound. Vehicle was a 1500 model at unspecified mileage.
When: Unspecified mileage; incident on highway
Symptoms owners cite: Right front tire shaking; Tire smoking; Tire ignition/fire
Severe rust and corrosion on undercarriage, frame (peeling in layers), brake lines, rotors, bumpers, wheels, bed, and door interiors despite low mileage (26,000 miles), careful maintenance, and avoidance of salted roads. Coolant line from radiator rusted through just before warranty expired (2009). Brake line burst while driving. Brake rotors required replacement twice. Owner filed complaint in 2010; dealer inspection found 'no abnormal rusting.' Subsequent brake line failure inspection yielded 'normal wear and tear' and 'environmental conditions' attribution despite two other vehicles (1993 Toyota and 2004 Volvo) in same conditions showing no such corrosion.
When: Rust noticed after first year (2007); coolant line failure at ~3 years (2009); brake line burst and rotor corrosion by ~10 years (2016)
Symptoms owners cite: Visible rust on undercarriage, frame, bumpers, wheels, bed, door interiors; Frame peeling rust in layers; Coolant line corrosion and failure; Brake line corrosion and rupture; Brake rotor and caliper corrosion
Repairs/costs cited: Rotors replaced twice; brake lines require replacement (cost not stated). Owner requested manufacturer coverage; denied as 'normal wear and tear.'
Recalls/TSBs owners mention: Dealer inspection (2010): 'No abnormal rusting found.' Subsequent dealer inspection (post-2016): corrosion attributed to 'environmental conditions' and 'normal wear and tear'; manufacturer declined to cover brake line replacement.
After dealership completed General Motors bulletin-specified exhaust pipe repair, brackets extended 3.5–4 inches from vehicle frame, creating collision hazard with road bumps. When manufacturer and dealership offered to return exhaust to original status, owner rejected solution as unacceptable.
When: Post-repair (timing unclear)
Symptoms owners cite: Exhaust brackets protruding 3.5–4 inches beyond frame; Risk of collision with road obstacles
Repairs/costs cited: Repair performed per GM bulletin; bracket protrusion created secondary safety issue.
Recalls/TSBs owners mention: GM bulletin-specified repair; manufacturer and dealer offered reversion to original state (not accepted by owner).
Vehicle stalled without warning while driving at ~10 mph on two separate occasions. Independent mechanic could not duplicate failure. Manufacturer notified but vehicle not repaired.
When: ~90,000 miles; two separate stall events
Symptoms owners cite: Vehicle stalls without warning; Occurs at low speed (~10 mph); Cannot be reproduced by mechanic
Repairs/costs cited: No repair attempted; failure not reproducible.
Recalls/TSBs owners mention: Manufacturer notified; no action taken.
Engine warning light illuminates with 'Reduce Power' message. Dealer unable to determine root cause or rectify problem.
When: Timing unspecified
Symptoms owners cite: Check Engine light illuminates; Reduce Power message displays; Power reduction (not quantified)
Repairs/costs cited: Dealer unable to diagnose or repair.
Synthesized from 39 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
It's a meaningful issue. 39 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $3,100.
Across the 33 complaints that reported odometer mileage, most engine failures cluster between 34,843 and 75,000 miles, with the median around 58,900. A quarter of owners report trouble before 34,843; a quarter make it past 75,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
Independent shops typically charge around $3,100 for engine repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Yes — 1 active recall(s) cover engine issues on this vehicle. Recall fixes are always free regardless of mileage or warranty status. Use the VIN decoder at the top of the page to check if your specific vehicle is affected.