Dive Brief:
- General Motors has recalled up to 597,630 SUVs and pickups equipped with 6.2L V8 engines due to a manufacturing defect involving the connecting rod and/or crankshaft that can lead to catastrophic engine failure, according to the National Highway Traffic Safety Administration.
- The recall follows a January investigation opened by the NHTSA after the agency received 39 reports of engine failures in GM vehicles, as well as three prior investigations by the automaker, which identified over 28,000 complaints potentially related to the issue.
- The recalled vehicles include the 2021-2024 Chevy Suburban, Tahoe and Silverado 1500 pickup; GMC Yukon and Yukon XL and Sierra 1500 pickup; and Cadillac Escalade and Escalade ESV models.
Dive Insight:
To address the recall, GM dealers will inspect and either repair or replace the engines if necessary for free. For vehicles that pass inspection, dealers will add higher viscosity oil and replace the oil filter and filler cap. Owner notification letters are expected to be mailed June 9.
It's not clear what oil viscosity GM will use to address the concern, but the owners manual for the 2022 Silverado equipped with a V8 engine, for example, calls for fully-synthetic 0w20 weight oil meeting “dexos1” specifications. The automaker warns customers that “failure to use the recommended engine oil or equivalent can result in engine damage not covered by the vehicle warranty.”
GM’s 6.2L V8 engine, which debuted in 2019 vehicles, is a standard design featuring overhead valves, a forged steel crankshaft and connecting rod bearing caps made of cast nodular iron.
But shortly after the engine’s debut, drivers of GM vehicles complained of unusual noises, as well as loss of power and no-start conditions. Some engine failures occurred without warning and on low-mileage vehicles. The complaints date back to 2022.
The automaker closed its previous investigations in February 2022, June 2023 and July 2024 based on the available safety field information it had at the time, therefore the root cause was not initially identified. However, a further analysis of field data by GM found that vehicles equipped with 6.2L V8 engines and produced between March 1, 2021, to May 31, 2024, showed a higher rate of failure claims, according to the NHTSA report.
After being notified of the NHTSA’s probe earlier this year, GM sequentially launched another investigation into the issue. Its latest teardown analysis identified two primary problems: “rod-bearing damage from sediment on connecting rods and crankshaft-oil passages” and “out of specification crankshaft dimensions and surface finish.” GM attributed both defects to supplier manufacturing and quality issues, although the supplier was not identified in the NHTSA recall report.
Through its findings, GM’s Safety Field Action Decision Authority elected to conduct a voluntary safety recall of the vehicles on April 17.
Between April 29, 2021, and February 3 of this year, GM identified over 28,000 field complaints or incidents in the U.S. market that are potentially related to crankshaft, connecting rod, or engine bearing failures in vehicles with V8 engines. Of this total, 14,332 involved allegations of loss of power leading to elevated safety concerns, including the risk of fire in rare cases. The automaker also identified 12 crashes and 12 injuries in the U.S. potentially related to sudden engine failures.
Manufacturing improvements were introduced into series production on or before June 1, 2024, which addressed engine crankshaft and connecting rod failure and contamination concerns for vehicles produced afterwards, according to the NHTSA report.
It's the second major recall for some of GM’s most popular SUV and pickup models, including for the 2020-2022 Silverado 1500 and GMC Sierra 1500. Last October, GM issued a recall for up to 462,000 trucks and SUVs for transmission control valves that are susceptible to excess wear over time, resulting in harsh shifting or rear-wheel lock up while driving in rare cases.
