General Motors has added a growing selection of electric models in every segment and badge on the Chevrolet, GMC, Cadillac, and Buick lineup and those highly-capable batteries now have a substantial place in the automaker’s long-term plans. The manufacturing focal point for those all-electric trucks like the Chevrolet Silverado EV and GMC Sierra EV at Factory Zero in Michigan includes keeping tabs on the complex systems within a truck the size of those battery-electric beauties through testing and recalls once they start getting to consumers.
In today’s electric pickup trucks, you get a mix of a complicated body structure design, a high voltage propulsion package, complicated electronics, and software driven safety features. Given the rapidly increasing complexity of these vehicles, periodic quality checks are a good idea for finding any manufacturing flaws before they become a costly problem on the public roadways. Once a defect is found, the N.H.T.S.A. Will coordinate with the manufacturer on getting the recall documented and instructions on repairing those owners’ vehicles.
In this article, I will investigate current and active safety recalls specifically affecting the GM full size electric trucks and related EVs. These recall campaigns affect a variety of component systems including (but not limited to) wheels, battery packs, drive units, software, seatbelts, electronic owners manuals and Pedestrian Warning Technology. Overall, these recall campaigns exemplify how safety in modern EVs relies heavily on testing and ongoing communication, and subsequent correction.
1. Chevrolet Silverado EV Wheel Recall
That makes GM’s latest effort in expanding its lineup of electric pickups through Chevrolet and GMC – including the Silverado EV and the upcoming Sierra EV – critical in its push into battery-powered trucks. Those vehicles come from GM’s own Factory Zero in Michigan, packing significant heavy-duty prowess in addition to electrified propulsion. More sophisticated means more need for stringent testing and regulation to catch manufacturing flaws before they cause major safety issues.
Key Issues Behind The Recall:
- 952 electric trucks affected
- Steel wheels contain manufacturing defects
- Cracks can develop around vent holes
- Wheel separation could cause control loss
- Dealers will replace defective wheels
This recall, NHTSA campaign number 26V496000, was reported on July 30, 2026. It involves 952 vehicles of the 2026 model year Chevrolet Silverado EV and GMC Sierra EV truck that was manufactured with steel wheels that have a manufacturing defect. The issue was brought to attention via supplier fatigue testing when engineers found that the wheel discs were possible of cracking around the disc vent holes under normal usage conditions.
If your wheel continues to crack it will eventually result in the separation of the disk from the wheel assembly, which in a loss of vehicle control would be a major safety hazard and a higher possibility for a crash. GM has issued a manufacturer recall number N262556920 where the dealer should check the wheel assemblies in question and replace faulty steel wheels at no charge to the consumer.
2. High-Voltage Battery Recall
GM has another campaign concerning high-voltage battery assemblies installed on multiple electric vehicle lines. The number of models and the production group are quite small, and the battery related recalls typically draw the highest amount of scrutiny due to the precise nature of the high-voltage systems of electric vehicles. The inspection process discovered a likely loose internal component of the battery before it became an epidemic of sorts.
Key Battery Safety Concerns:
- Only 10 vehicles are affected
- Multiple 2026 EV models included
- Internal battery component may loosen
- Movement could damage nearby components
- Complete battery assembly replacement required
An NHTSA campaign, 26V494000, with a filing date of July 30, 2026, covers 10 vehicles of the 2026 model year and includes the Cadillac Escalade IQ, Cadillac Escalade IQL, GMC Sierra EV, and Chevrolet Silverado EV. Factory inspections revealed that a component within the high voltage battery pack may not have been secured during manufacturing.
Should that component shift position during operation of the vehicle then there exists a possibility it could come into contact and damage other high-voltage components contained within the battery enclosure. Damage to any of the battery cells or electrical wiring could pose an increased fire risk of the vehicle. GM allocated recall number N262562600 and will replace the entire high-voltage battery assembly free of charge to the consumer.
3. Electronic Stability Control Software
Software plays an important role on modern electric trucks as the mechanical components. GM found a problem with the electronic stability control warning light on some Silverado EVs and Sierra EVs. The stability control module could fail in certain situations, but the instrument cluster would not give the proper warning on a subsequent restart of the truck.
Key Software Problems Identified:
- 1,191 vehicles are affected
- Silverado EV and Sierra EV
- Warning indicator may fail
- Software does not meet FMVSS
- Dealers can reprogram affected modules
NHTSA campaign 25V594000 was noted on September 11, 2025 for 1,191 electric pickup trucks sold in the United States, and 84 more vehicles sold in Canada. Within the U.S. Vehicle contingent are 567 2026 Chevrolet Silverado EVs and 624 2026 GMC Sierra EVs that were built at Factory Zero in Michigan prior to June 24, 2025.
The defect is related to the Electronic Stability Control warning indicator. After an electronic stability control system failure event, the warning light may not be illuminated the next time the vehicle is started, causing the driver not to realize an issue is present. GM designated recall number N252515340; the fix will involve reprogramming the electronic brake control module and may also be achieved through an over-the-air (OTA) update.
4. Electronic Owner Manual Problem
The safety recalls not only encompass the physical parts that operate and stop the car. General Motors also recalled its digital owner’s manual and affected multiple Chevrolet, GMC, Cadillac, and Buick vehicles due to a factory radio setting incorrectly installed that disabled vehicles from downloading the necessary electronic manual.
Key Documentation Issues Identified:
- 5,861 vehicles are affected
- Multiple GM brands included
- Factory radio setting was incorrect
- Electronic manual may not download
- Dealers will reset radio systems
The Campaign number for this was Campaign number 26V114000 which was declared on February 26, 2026, and will affect about 5,861 vehicles under various GM’s brand cars. The affected 2027 Chevrolet Bolt EV, Chevrolet Silverado 1500, multiple Cadillacs, various Chevrolet electric vehicles, Buick vehicles, electric GMC vehicles, and Chevrolet Silverado 2500.
Due to misconfiguration the electronic owner’s manual may not download to the radio of your vehicle, this failure is also part of violations in Federal Motor Vehicle Safety Standard 208 and may not allow people access of necessary driving instruction and safety measures, GM is calling it N252540430 and they will perform radio reset to customers of free.
5. Rear Electric Drive Unit Recall
For a high voltage electric drive module, the wiring, assembly and insulation process must be very stringent as even a slight electrical anomaly can impact propulsion. GM has identified such an issue in some 2024 electric vehicles like Silverado EV and Sierra EV. The rear drive units had wires that were under insulated and may come into contact with each other.
Key Electrical Fault Concerns:
- Only 10 vehicles affected
- Several 2024 EV models included
- Rear motor wires lack insulation
- Electrical contact could cause shorts
- Complete drive unit replacement required
The NHTSA campaign 24V320000 was issued May 9, 2024 and a total of 10 vehicles from GM’s 2024 offerings. The Cadillac Lyriq, Chevrolet Blazer EV, Chevrolet Silverado EV, GMC Hummer EV SUV, and GMC Sierra EV are affected, Engineers found wires inside the rear electric motors were not adequately insulated.
There is a potential for electrical short circuit in the rear drive unit, if the wires contact each other. This could lead to abrupt loss of drive, while operating the vehicle, and thus potential to crash. GM issued recall number N242447080 and told the dealer to replace the whole rear drive unit at no cost to vehicle owners .
6. Rear Center Seat Belt Recall
Seat belts continue to be a necessary safety device, even in state-of-the-art electric trucks. The Silverado EV and Sierra EV suffered from two distinct seat belt problems on early production units, according to GM. One was hardware not tightened sufficiently to hold the rear center seat belt assembly in place. The second was an improperly specified bezel that could cut the belt in a severe crash.
Key Restraint System Problems:
- Five vehicles had loose bolts
- Silverado EV and Sierra EV
- Center belt anchor lacked proper torque
- Incorrect bezel could damage webbing
- Dealers performed corrective repairs
NHTSA campaign 25V015000 was documented on Jan 16, 2025, and was in relation to 2024 Chevrolet Silverado EV and 2024-2025 GMC Sierra EV models in a number of 5 cars. The reason for recall N242489901 was that the rear center seat belt assembly bolt had not been tightened according to GM’s original factory specification. Since none of the affected cars had left the dealer floor all 5 cars were addressed prior to customer delivery.
Then on Feb. 8, there was the “NHTSA 24V087000” recall, of 338 2024 Silverado EV model years. That’s because the wrong kind of bezel had been incorrectly fitted on the second row center seat belt system. If the truck experienced a severe crash, “the bezel may rub against the belt webbing, which may cause damage or abrasion,” resulting in wear or an “unprotected and untended strap,” GM said. Owners were told not to use the rear center seat at all until GMs installed the correct piece.
7. Pedestrian Alert Sound Recall
Quiet by nature of being electric, these vehicles introduce new challenges for pedestrians at lower speeds. GM found in a set of Silverado EV work trucks that an external audible warning sound failed to meet the required volume level. This was deemed critical for commercial vehicles that frequent the paths of employees, pedestrians and crowded work sites.
Key Acoustic Safety Concerns:
- 46 work trucks affected
- 2025 Silverado EV included
- External warning sound was insufficient
- FMVSS 141 requirements were violated
- Software update corrects speaker output
There was a registered NHTSA campaign, 24V937000, initiated on December 18, 2024, that recalled 46 units of the 2025 Chevrolet Silverado EV work truck. Audits revealed that a warning to pedestrians outside the electric truck was not emanating from the warning sound system at the appropriate volumes. Because electric trucks can be extremely quiet at low speeds, insufficient warning sound might hinder pedestrians.
In the report (which also included defect related owner information and GM Part #23187571 Pedestrian Alert Output Modulator), they noted that manufacturer recall number N242483530 for which dealerships are requested to reprogram the body control module (BCM) of the vehicles at no cost. In addition, a free software update on dealers.net, reprogram the pedestrian alert speaker output such that it meets the requirements mandated by the Federal Motor Vehicle Safety Standard No. 141. Mail was sent out to owners January 22, 2025, providing affected operators notice and contact details.
8. Factory Zero And EV Production
GM’s Factory Zero assembly plant in Michigan plays an important role in the company’s electric vehicle strategy. The facility produces several major electric models, including the Chevrolet Silverado EV and GMC Sierra EV, while also supporting GM’s broader transition toward battery-powered transportation. As production expands, manufacturing quality control remains essential for identifying problems involving hardware, software, and electrical systems.
Key Factory Zero Responsibilities:
- Builds major GM electric trucks
- Located in Michigan
- Supports large EV production
- Integrates advanced battery technology
- Handles complex vehicle systems
The Silverado EV uses GM’s dedicated BT1 electric platform rather than sharing the same underlying architecture as the gasoline-powered Silverado. The electric pickup uses a unibody construction, all-wheel drive, permanent-magnet motors, and an Ultium lithium-ion battery system. Its long-range configuration has been advertised with substantial driving range, highlighting how GM has positioned the truck for both work and long-distance travel.
The GMC Sierra EV serves as the closely related GMC counterpart, while the platform is also associated with vehicles such as the GMC Hummer EV and Cadillac Escalade IQ. The Silverado EV entered production in May 2023 for the 2024 model year, giving Chevrolet a dedicated full-size electric pickup after earlier experimental electric truck projects such as the S-10 EV.
9. GM’s Recall And Repair Strategy
The various recall campaigns demonstrate how modern vehicle safety involves far more than checking engines, brakes, or suspension components. GM’s electric trucks combine high-voltage batteries, electric drive units, software-controlled systems, digital displays, pedestrian warning technology, and conventional occupant restraint hardware. Each system requires its own testing procedures and corrective strategies when a potential defect appears.
Key Safety Response Measures:
- Recalls identify specific production defects
- NHTSA monitors federal campaign
- Dealers perform required repairs
- Software updates fix digital problems
- Repairs are provided without charge
GM uses several different repair methods depending on the problem involved. Wheel defects require physical replacement, battery problems can require complete battery assembly replacement, and drive-unit concerns may require replacing the entire rear drive unit. Software-related problems can often be corrected through dealership reprogramming or, where supported, over-the-air updates.
Owners can verify recall information using their Vehicle Identification Number through NHTSA’s recall system or by contacting the relevant GM brand’s customer service department. This combination of regulatory oversight, manufacturer testing, dealership repairs, and digital software support allows problems to be addressed before they become larger safety concerns.
10. The Future Of GM Electric Trucks
GM’s expanding electric truck program illustrates how quickly automotive engineering has moved beyond traditional mechanical systems. The Silverado EV and Sierra EV combine immense pickup capability with battery propulsion, sophisticated software, digital displays, and advanced safety technology. That complexity creates new engineering challenges, but it also gives manufacturers more ways to detect and correct potential problems.
Key Lessons From These Recalls:
- EV safety requires constant monitoring
- Hardware and software both matter
- Battery systems demand careful oversight
- Regulatory testing protects vehicle occupants
- Quick repairs preserve customer confidence
The recall campaigns involving wheels, batteries, drive units, seat belts, software, electronic manuals, and pedestrian alerts show why continuous quality control is essential. Some campaigns involve hundreds or thousands of vehicles, while others affect only a handful. Regardless of the size, identifying the problem and providing a clear remedy remains central to protecting drivers and passengers.
As full-size electric pickups become increasingly common on highways, construction sites, and commercial fleets, safety oversight will remain an important part of their development. GM’s approach demonstrates how modern manufacturers combine physical inspections, component replacement, software reprogramming, and over-the-air updates to address defects. The continued evolution of these systems will shape how electric trucks deliver the performance, capability, and confidence expected from the next generation of pickup vehicles.
