To take the least amount of risk we can’t do anything to our trucks. There are some dealerships that are that fussy about any mods. Other dealerships are less fussy. Also, I don’t think we even have to use the dealer for warranty and extended warranty work—just need an approved repair facility, though I would thoroughly research that first.
So the question becomes how much risk are we willing to take? The extreme end of the spectrum is putting a BIG HP tune in a Duramax. If we thrash the trans while doing that we aren’t going to get warranty coverage and rightly so. On the other end, putting an intake, cat back, and mild tune in a gas engine is unlikely to make enough extra power to break anything.
I am am doing an AFE intake, Borla cat back, and Superchips tune for my year-old 2018 5.3 with 13,000 miles on it. Superchips said that an intake and cat back with their canned performance tune will add about 30 HP. The risk of breaking something with that is very low, and if I do need warranty work I’ll put the stock tune back in and maybe the stock intake. Most dealers I have dealt with say to bring it in stock—I don’t expect any issue with a cat back.
With two different tuned Duramaxes all I did was flash back to stock and the dealer covered the repair, but the warranty items were small—a sensor and a TCM. I wasn’t trying to cover a fried transmission. Big tunes in the Duramax without beefing the trans and then trying to get warranty on damaged drivetrain components are a big part of why GM got so fussy about mods and warranty, Magnuson-Moss Act notwithstanding.
Also, Superchips offers a two-year powertrain warranty, which eases the risk even more.