HVAC Evaporator Core Leaks (GM SUVs & Trucks)

Many late-model GM full-size trucks and SUVs are known for weak HVAC evaporator core designs that develop refrigerant leaks. Repairing these leaks typically requires extensive dash removal, making the job very labor-intensive and expensive.

This is one of the most complained‑about HVAC failures on GM trucks/SUVs from the mid‑2010s. Patterns include:

A/C stops blowing cold suddenly
Dye test reveals evaporator leak
Dealers quote $1,500+
Many failures occur between 40k–80k miles
Some owners report multiple failures
2018+ use R-1234yf

It’s widespread enough that:

GM issued TSBs
GM revised the evaporator design in later years
Independent shops stock aftermarket upgraded cores because demand is so high

Year(s)	Make	Model	Should Purchase?	Reason	Notes
2014 2015 2016 2017 2018	Chevrolet	Silverado 1500	Caution	Known for evaporator core leaks	Weak HVAC evaporator design. Dash removal required to replace core; labor cost is high.
2014 2015 2016 2017 2018	GMC	Sierra 1500	Caution	Same evaporator weakness as Silverado	Refrigerant leaks lead to loss of A/C performance. Repair involves full or partial dash removal.
2015 2016 2017 2018 2019 2020	Chevrolet	Tahoe	Caution	Evaporator core prone to leaking	Common A/C loss due to evaporator leaks. Access requires significant interior disassembly.
2015 2016 2017 2018 2019 2020	Chevrolet	Suburban	Caution	Same HVAC evaporator issue as Tahoe	Weak evaporator design; leaks often appear as the vehicle ages. Dash removal makes repair costly.
2015 2016 2017 2018 2019 2020	GMC	Yukon	Caution	Evaporator core leak-prone	A/C performance degrades as refrigerant escapes. Dash removal required to access evaporator housing.
2015 2016 2017 2018 2019 2020	GMC	Yukon XL	Caution	Same HVAC design vulnerability as Tahoe/Suburban	Known for evaporator leaks in the HVAC case. High labor time due to deep interior access.
2015 2016 2017 2018 2019 2020	Cadillac	Escalade	Caution	Luxury model with same evaporator weakness	Evaporator core leaks despite premium branding. Dash-out repair makes failures especially expensive.

Summary

HVAC evaporator core leaks on late-model GM full-size trucks and SUVs are a known weak point and require invasive dash removal to repair. Even though the parts themselves are not extremely expensive, labor costs make this a significant long-term ownership concern compared to platforms with more robust HVAC designs.