This Preliminary Information communication advises the technician that if OnStar is unable to configure the vehicle after the OnStar 15-08-44-001 upgrade and Onstar receives a 118 error code when attempting to configure the vehicle. Dealers should receive a sheet with the kit that provides steps to assist with handling this error. Dealer will follow one of the listed steps to resolve the issue. If there are still configuration issues, please contact the OnStar Technical Assistance Centre for assistance.
full bulletin at NHTSA ↗2007 GMC Sierra electrical problems
severe 29 complaints filed with NHTSA · avg repair $850 · see electrical across all vehicles →
Owners have filed 29 electrical complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering electrical 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.
CADILLAC/CHEVROLET/GMC: ON SOME VEHICLES AND/OR TRUCKS, INSTRUMENT CLUSTER WILL ILLUMINATE, AFTER AN OIL CHANGE, INDICATING LOW OIL PRESSURE AND/OR SES LAMP WILL ILLUMINATE. MODEL 2007-13 CANYON, SIERRA, SAVANA, YUKON, CTS-V, ESCALADE, AVALANCHE, CAMARO SS, COLORADO, CORVETTE, EXPRESS, SILVERADO, SUBURBAN, TAHOE.
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 ↗GENERAL MOTORS: INTERMITTENT MIL/SES/ DTC P2138 WITH REDUCED ENGINE POWER (REPAIR INSTRUMENT PANEL (IP) TO BODY HARNESS CONNECTOR). 2005-08 GM PASSENGERS CARS/LIGHT DUTY TRUCKS (INCL. SATURNS). UPDATED 11/5/10. UPDATED 4/4/11. UPDATED 2/3/16.
full bulletin at NHTSA ↗This Preliminary Information communication provides information to the technician about vehicle that may have an OnStar system that has progression tones when pressing the blue or red button. Technician will need to call General Motors Technical Assistance Center with the scan tool data from the OnStar system.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners consistently describe intermittent power loss events where the engine shuts down without warning at highway speeds, forcing them to wiggle battery cable connections to restore function. Multiple narratives cite similar symptoms: door locks cycling, check engine lights, gauge clusters resetting, and complete loss of power steering and brakes. Battery connections to the frame and fuse panels appear loose, and NHTSA reference #10036550 and TSB #PIT-4730A document this across GM and Chevy models.
Electrical fires are a recurring theme. The HVAC system blower resistor overheats and melts, filling the cabin with smoke and burning plastic smell. Exposed wiring scrapes against the frame, and melted instrument panel wiring has ignited. One vehicle caught fire completely while being driven with a child aboard.
Brake light malfunction disables cruise control; one owner reports the body control module replacement was only temporary, requiring a second component replacement for permanent fix. Airbag systems fail to deploy or have warning lights that remain on after service. Some owners' vehicle VINs exclude them from available recalls despite facing identical failures.
The instrument panel becomes unreadable in daylight because an automatic dimming photosensor sits in shadow from the wiper assembly. Several owners report dealer inability to diagnose intermittent stalling, with service visits finding nothing wrong—then the vehicle dies again on the highway. One owner had to swap relays repeatedly to get the truck running.
Same GMC Sierra electrical reports on nearby years: 2005 · 2006 · 2008 · 2009 · 2010
Failure modes owners describe
Brake light malfunction / BCM failure
Brake lights stay on continuously or illuminated in reverse (stay on while driving, turn off when braking), disabling cruise control. Condition caused intermittent power loss and was temporarily fixed by body control module (BCM) replacement, but recurred within 7 months. Dealership stated BCM replacement was only a temporary fix and a second component replacement was needed for permanent resolution.
When: Replaced 02/15/2016; issue recurred within 7 months
Symptoms owners cite: Brake lights stay on while driving; Brake lights turn off when vehicle is slowing down or stopped; Cruise control disabled; Brake operation reversed
Repairs/costs cited: BCM replaced at dealership cost $10 part + $150 labor (02/15/2016). Second component replacement quoted at $150 but declined by owner. GMC offered $2,000 voucher toward new or used vehicle (later rescinded due to vehicle mileage exceeding 100,000 miles).
Recalls/TSBs owners mention: GMC acknowledged issue exists on Chevy Malibu same year. Customer service offered $2,000 voucher but rescinded it when vehicle exceeded 100,000 miles. GMC stated unable to resolve safety issue; further repairs would be at owner expense.
HVAC blower motor resistor overheating and burning
HVAC system ran continuously even with ignition off while vehicle parked in garage. Relay resistor module overheated, melting the resistor and circuit board. Vehicle cabin filled with smoke and strong burning plastic smell. Owner had to disconnect wiring harness to stop the burning. Condition identical to Transport Canada Recall #2011074.
When: Vehicle parked in garage; exact mileage unknown
Symptoms owners cite: HVAC system running with ignition off; Burning plastic smell in cabin and garage; Smoke filling vehicle cabin; Melted resistor and circuit board
Repairs/costs cited: Dealer replaced blower motor, resistor, module connector, and relay. Owner noted burning could have caused entire vehicle to catch fire.
Recalls/TSBs owners mention: Transport Canada Recall #2011074 describes identical scenario.
Heated washer fluid module fire hazard
Vehicle equipped with heated washer fluid module. Manufacturer notified owner that module needed to be removed to prevent possible fire. Owner declined removal because heated washer fluid was determining factor in purchase decision due to climate in area.
When: At 54,000 miles
Symptoms owners cite: Possible fire hazard from heated washer fluid module
Repairs/costs cited: Module removal recommended but not performed by owner.
Recalls/TSBs owners mention: NHTSA Campaign ID 10V240000 (Electrical System) issued. Manufacturer advised module removal but stated nothing could be done to assist if owner refused.
Intermittent power loss / battery cable connection failure
Vehicle experiences intermittent complete power loss, causing engine shutdown without warning. Door locks cycle, check engine lights illuminate, gauge clusters reset. Owner must wiggle battery terminal cables to restore power. Issue occurs at various speeds including 80 MPH, creating extreme safety hazard. Affects multiple GM and Chevy models. Referenced NHTSA #10036550 and TSB #PIT-4730A. Root cause identified as loose battery cable attachments to frame and fuse panels.
When: Intermittent; occurred at 80 MPH and during other driving
Symptoms owners cite: Complete engine shutdown without warning; Door locks cycling up and down; Check engine lights illuminating; Gauge cluster resetting; Complete power loss to steering, brakes, and engine; Vehicle unable to crank until power restored manually
Repairs/costs cited: Power restored by manually wiggling battery terminal cables. No permanent repair documented.
Recalls/TSBs owners mention: NHTSA reference #10036550 and TSB #PIT-4730A exist for this condition. Condition affects wide variety of GM and Chevy models.
Ignition switch failure
Vehicle independently shuts off while driving at various speeds without warning. Jiggling key in ignition cylinder causes restart. Failure is intermittent but recurring. Independent mechanic diagnosed defective ignition switch requiring replacement and noted recall exists for this failure.
When: At 183,000 miles; intermittent occurrences
Symptoms owners cite: Vehicle shuts off while driving; No warning lights illuminated before shutdown; Vehicle restarts when key jiggled in ignition
Repairs/costs cited: Independent mechanic diagnosed and recommended ignition switch replacement. Vehicle not repaired.
Recalls/TSBs owners mention: Dealer told owner no recall exists; owner researched and found NHTSA Campaign 15V640000 (Electrical System). Mechanic stated recall exists but dealer denied it.
Relay and fuse bank failures
Intermittent loss of engine power and ability to crank. Swapping relays temporarily restores function. First incident occurred with parked vehicle (no power, no turnover, no instrument panel). Second incident occurred while driving on road, causing engine to die without warning. Owner must swap relays in crank/run and start relay positions to restore function; does not replace relays but swaps with others.
When: First incident approximately 3 months before complaint; second incident with wife driving
Symptoms owners cite: Complete power loss while parked; No instrument panel lights; Engine will not turn over; Engine dies while driving on road; No warning before power loss
Repairs/costs cited: Temporary fix achieved by swapping relays. No permanent repair or replacement made.
Electrical fire from wiring harness and blower motor resistor
Smoke began to engulf vehicle while driving at 55 MPH. Wiring melted on instrument panel from unknown cause. Dealer identified wiring harness and resistor for blower motor as source. Second incident of similar nature in narratives (narrative #8 is almost identical).
When: At 40,000 miles
Symptoms owners cite: Smoke engulfing vehicle; Melted wiring on instrument panel
Repairs/costs cited: Dealer stated wiring harness and resistor for blower motor needed replacement.
Recalls/TSBs owners mention: Manufacturer declined financial responsibility because vehicle exceeded warranty.
Wiring exposed to frame causing electrical fire
After routine maintenance, fire started under front of truck as it was being pulled out of garage. Upon fire extinguishment, mechanic discovered exposed wiring that had been continuously scraping against truck frame.
When: 11/10/15 after routine maintenance and startup
Symptoms owners cite: Fire under front of truck; Exposed wiring from continuous frame scraping
Repairs/costs cited: Fire required extinguishing.
Electrical fire in engine compartment
Vehicle caught fire while being driven with child in back seat. Fire started in engine compartment and traveled throughout vehicle before fire department arrival. Over 3/4 of vehicle was totally burned. Owner able to exit with child before fire reached interior.
When: 04/23/2009 while driving with child
Symptoms owners cite: Vehicle fire in engine compartment
Dashboard circuit breaker box detachment
Circuit breaker box fell off vehicle and landed behind brake pedal while driving at 80 MPH in rain. Owner had to stop vehicle with emergency brake. Issue occurred at very low mileage, suggesting design defect in attachment.
When: At 1,700 miles
Symptoms owners cite: Circuit breaker box fell off vehicle; Box landed behind brake pedal
Instrument panel illumination failure / automatic dimming malfunction
Instrument panel lights fail to illuminate or are not readable during daylight or when vehicle is parked in shadow. Dashboard lights only kick in after vehicle has been in bright sun for 10-45 minutes. Appears to be electric eye (photosensor) location issue: sensor is shadowed by windshield wiper assembly or passenger side pillar. Affects speedometer, RPM, fuel, oil, and water gauges but odometer/DIC and gear indicator illuminate. Problem reported by multiple GMC and Chevy pickup truck owners.
When: At 1,200-1,700 miles and ongoing; affects daytime and shaded parking
Symptoms owners cite: Instrument panel not lighted when parked overnight or in shadows; Lack of illumination for 30-45 minutes after startup; Speedometer, RPM, fuel, oil, water gauges not readable; Odometer/DIC and gear indicator illuminate normally; Radio display cannot be read from driver position
Recalls/TSBs owners mention: GM document ID# 1879131 dated 12/19/06 shows GM is aware of problem.
Electrical system power loss causing stalling and loss of steering/brakes
Engine shuts down while driving with no warning, causing loss of power steering and braking. 'Service Brake System' message appears in display and ABS light illuminates. First incident occurred first year of ownership; fuse box replaced. Second incident caused blown PCM fuse. Third incident on highway during rush hour required replacing fuse 5 times to get off freeway; fuse blew again after each 1-2 miles of driving.
When: First incident first year of ownership; subsequent incidents in March (13th and 29th)
Symptoms owners cite: Engine shuts down while driving; Loss of power steering; Loss of braking; 'Service Brake System' message displayed; ABS light illuminates; No warning before shutdown
Repairs/costs cited: Fuse box replaced first time. Blown PCM fuse replaced second time. Fuse needed replacement 5 times during third incident.
Recalls/TSBs owners mention: Dealer unable to find anything wrong after second incident; stated 'nothing wrong' could be found.
Airbag seat presence switch wire breakage
Wire connecting airbag 'person in seat' switch breaks when seat is slid all the way back. Owner states manufacturer knows about this issue but has not recalled truck. Airbag will not deploy when needed.
When: When seat positioned all the way back
Symptoms owners cite: Wire connecting airbag person-in-seat switch breaks; Airbag will not deploy when needed
Recalls/TSBs owners mention: Owner states manufacturer knows about problem but refuses to recall or pay to fix.
Takata airbag recall delay and non-deployment issue
Vehicle involved in accident at 35 MPH (sandwiched between two cars); airbag did not deploy. Vehicle sent to body shop for $7,000 in damage repair. After return from body shop, airbag light came on and stayed on. Owner was told in July 2016 by GM that no Takata recall existed for this vehicle. On August 11, 2016, owner received recall letter. When owner called to complain about delay, GM hung up on owner. Dealer unable to make appointment to fix Recall #49152 as of 8/12/16, stating parts could take up to one year. Mechanic states when airbag light is on, bags will not work. Owner states NHTSA Part 573 Safety Recall Report shows all 2007 GMC Sierras in high-humidity areas were to be recalled as of May 27, 2016, but owner did not receive letter until August 11.
When: Accident occurred at unknown date; recall letter received 08/11/2016
Symptoms owners cite: Airbag did not deploy at 35 MPH impact; Airbag warning light on after body shop repair; Airbag light remains illuminated; Owner reports airbag inoperative when light is on
Repairs/costs cited: Dealer has no parts available as of 8/12/2016; estimates one year for parts availability. No appointment made.
Recalls/TSBs owners mention: Recall #49152; NHTSA Campaign for Takata recall exists. GM initially told owner (07/01/2016) no recall existed, then sent recall letter 08/11/2016. When owner complained about delay, call was disconnected.
External mirror folding mechanism failure
Electrically powered folding external mirror assembly became inoperable, causing entire mirror assembly to become loose. Mirror moves back and forth while driving, creating false sense of vehicle or adjacent vehicle movement. Distraction is significant enough to potentially induce vertigo and lead to catastrophic driving results.
When: Unknown mileage
Symptoms owners cite: Electrically powered folding mirror becomes inoperable; Mirror assembly becomes loose; Mirror moves back and forth while driving; False perception of vehicle movement
Smoke and burning from air conditioning system
While driving at 55 MPH, smoke came through vents along with burning odor. Air conditioning was activated when smoke started. Turning off air conditioning stopped the smoke. Owner never used air conditioning again. Most electrical lights on instrument panel then started to illuminate. Mechanic stated failure was caused by throttle sensor or catalytic converter but neither was identified as definitive cause.
When: At 74,616 miles
Symptoms owners cite: Smoke coming through vents; Burning odor; Electrical lights on instrument panel illuminating
Repairs/costs cited: Vehicle not repaired. Mechanic suspected throttle sensor or catalytic converter.
Recalls/TSBs owners mention: Manufacturer not notified by owner.
Speedometer gauge fluctuation and electrical system flashing
While driving at various speeds, traction control warning light illuminated, internal/external lights independently flashed on/off, door locks independently locked and unlocked. Speedometer gauge fluctuated from 30 to 50 MPH.
When: Unknown mileage
Symptoms owners cite: Traction control warning light illuminates; Internal lights independently flashing on/off; External lights independently flashing on/off; Door locks independently lock and unlock; Speedometer fluctuates 30-50 MPH
Repairs/costs cited: Dealer unable to determine failure.
Engine stalling with no warning and ignition problem
While stopped at traffic light, speedometer jumped from 0 to 10 MPH and higher with no instrumentation warning. Engine then stalled with no indicator signals at all. Owner restarted engine after placing shift in park and turning key.
When: At moderate traffic during daytime
Symptoms owners cite: Speedometer jumping 0 to 10+ MPH at stop; No instrumentation warning before stall; Engine stalls; No indicator signals
Repairs/costs cited: OnStar diagnostic indicated 'ignition problem'.
Recalls/TSBs owners mention: OnStar diagnostic reported ignition problem; OnStar recommended dealer appointment.
Heater blower motor continued operation when off / resistor overheating
Heater motor continues to run after switch is turned off. Blower only works randomly. Owner aware of recall but VIN not included. Identified risk of electrical fire because motor can run with switch off. Similar issue affects number of different GM vehicles.
When: Unknown mileage
Symptoms owners cite: Heater motor runs after switch is turned off; Blower only works randomly; Possible electrical fire risk
Repairs/costs cited: Owner familiar with recall but VIN excluded from campaign.
Recalls/TSBs owners mention: Recall exists but vehicle VIN not included.
Heater failure with overheating wiring
Heater failed; motor operates but no heat emits from vents. Dealer identified overheating wiring and stated wiring harness needed replacement. Vehicle not repaired.
When: At 95,000 miles
Symptoms owners cite: Heater motor operates but no heat output; Wiring overheating
Repairs/costs cited: Dealer stated wiring harness replacement needed.
Recalls/TSBs owners mention: Manufacturer notified; advised vehicle not included in any recall.
Intermittent power loss and stalling
Vehicle stops in middle of traffic without warning. Has occurred 4 times since purchase. Dealer cannot find anything wrong. Most recent incident vehicle would not move at all; owner pushed to side of road by bystander. Battery died 4 months after purchase. DVD player installation failed 3 months after dealer installation.
When: Multiple incidents since purchase; 4 months after purchase battery died
Symptoms owners cite: Vehicle stops in middle of traffic; Vehicle will not move; Battery dies
Repairs/costs cited: Battery was only component replaced. DVD player not repaired; dealer blamed customer.
Recalls/TSBs owners mention: Dealer unable to find problem despite multiple incidents.
Partial power loss with cycling door locks and flickering gauges
Vehicle loses partial power. Door locks cycle up and down. Gauges and lights flicker. Cruise control turns off. Lights turn on if running lights are off.
When: Unknown mileage
Symptoms owners cite: Partial power loss; Door locks cycle; Gauges flicker; Lights flicker; Cruise control disables; Running lights turn on unexpectedly
General electrical system issues (multiple)
Multiple unspecified electrical issues reported: airbag system issue, tire monitoring system light always on, door lock/unlock issues, check engine light issue.
When: Unknown mileage
Symptoms owners cite: Airbag system malfunction; Tire monitoring system light always on; Door lock/unlock issues; Check engine light issue
Ignition and airbag system failure
Vehicle would not start. Ignition would not work. Airbag issues present.
When: Unknown mileage
Symptoms owners cite: Vehicle will not start; Ignition will not work; Airbag system failure
Miscellaneous electrical and burning concerns
Reports of burning plastic smell from air vents, radiator fans always running, tire monitoring system light always on, check engine warning, air conditioning turning off, engine overheating warnings.
When: At 55,000 miles and ongoing
Symptoms owners cite: Burning plastic smell from air vents; Radiator fans always running; Tire monitoring system light always on; Check engine warning; Engine hot warning; Air conditioning turning off; Brake burning smell; Noise in rear end
Repairs/costs cited: Power steering hose leaking. Truck at dealer attempting repairs.
Synthesized from 29 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 0 most recent
Common questions
How serious is the electrical problem on the 2007 GMC Sierra?
It's a meaningful issue. 29 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $850.
At what mileage does the electrical typically fail?
Across the 21 complaints that reported odometer mileage, most electrical failures cluster between 40,000 and 95,000 miles, with the median around 55,000. A quarter of owners report trouble before 40,000; a quarter make it past 95,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $850 for electrical 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.
Are there any recalls related to electrical?
No active recalls currently cover electrical issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.