2004 Chevrolet Silverado 3500
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Chevrolet › Silverado 3500 › 2004
These records cover every 2004 Chevrolet Silverado 3500. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
1 recall names the 2004 Chevrolet Silverado 3500. Newest first.
Certain replacement fuel filters, fram brand name p/n g3727, with date codes x52911 through x60801 sequentially or x600141 and a mexico country or origin marking on the fuel filter housing manufactured from october 18, 2005, through march 21, 2006, sold for use on the vehicles listed above and on certain school buses. (to see the school bus engine sizes…
Risk and remedy
Risk
This condition may cause an inadequate seal at the connection, potentially leading to a fuel leak. In the presence of an ignition source, a fire could occur.
Remedy
Honeywell will notify owners and replace the fuel filters free of charge. the recall began on october 18, 2006. owners may contact fram customer service at 1-800-890-2075 (option 1).
Owner complaints
41 complaints5 involved a crash3 injuries
What owners report most
Latest complaints
- Service brakes
All factory hard brake lines have failed due to corrosion. I've replaced the intermediate line between the master cylinder and distribution block with stainless steel 1.5 yrs ago. I just replaced the rear brake lines along the axel. Now the front brake lines have failed. In all cases the lines failed while driving and emptied the master cylinder. I do not live in the salt belt.
- Service brakes
Brake line failure due to rusted & corroded brake lines resulting in costly repairs. Luckily my 2004 chevy silverado 3500 was stationary when brake line ruptured and I was not towing a trailer or loaded with cargo at the time of failure. The ABS pump also failed prior to line failure. My father in…
Brake line failure due to rusted & corroded brake lines resulting in costly repairs. Luckily my 2004 chevy silverado 3500 was stationary when brake line ruptured and I was not towing a trailer or loaded with cargo at the time of failure. The ABS pump also failed prior to line failure. My father in law had similar issues with the same model year 1500. Why does gm not use stainless brake lines for such an important safety component.
- Fuel/propulsion system · Service brakes
2 problems: 1- while driving with no warning the brakes failed. After coasting to a stop I noticed a brake line had ruptured at the frame rail under driver area. I was able to crimp brake line with a pair of vice grip pliers and move truck to a safe location for repair. I believe the brake lines…
2 problems: 1- while driving with no warning the brakes failed. After coasting to a stop I noticed a brake line had ruptured at the frame rail under driver area. I was able to crimp brake line with a pair of vice grip pliers and move truck to a safe location for repair. I believe the brake lines used on these trucks to be of such inferior quality that sudden failure IS a common occurrence. 2- my truck has dual tanks for diesel fuel and they have worked sporadically for years. I did not see this as a safety issue as much as an inconvenience. however while my truck was idling on a hot summer day I noticed diesel fuel dripping out of the front tank filler cap. apparently the pump that pumps the fuel from the rear tank to the front tank was receiving a signal to pump even though the front tank was completely filled. it was continuing to pump and leaking the fuel out the filler neck. this seems like a serious safety hazard to me. I do not know if the root of the problem IS the float that sticks in the rear tank, the sending units that fail, a wiring ground issue or some other electronic glitch. I do know issues with dual tank duramax diesel trucks are about as common as the truck itself IS. after researching online I realized many other owners of my vehicle model have had both of the exact same problems so I thought I should report them.
- Structure › Body
TL* the contact owns a 2004 chevrolet silverado 3500. The contact stated that the rocker panels located under the doors on both the driver and passenger side of the vehicle were rusted and corroded. The vehicle was taken to the dealer who did not repair the vehicle. The contact indicated that the…
TL* the contact owns a 2004 chevrolet silverado 3500. The contact stated that the rocker panels located under the doors on both the driver and passenger side of the vehicle were rusted and corroded. The vehicle was taken to the dealer who did not repair the vehicle. The contact indicated that the steel inside the rocker panel was not painted and contributed to the rusting. The cause of the failure was not diagnosed or repaired. The manufacturer was not notified of the failure. The vin was not availiable. The failure mileage was 40,000.
- Service brakes
Front brake lines failed causing fluid loss and complete loss of brakes. happened at slow speed, but still was unable to stop before hitting a fixed object
- Service brakes
In march while driving my 2004 chevy 3500 diesel truck the brake warning lights inside the cab lit up and the brake pedal was feeling spongy. I took it into classic auto group mentor for service. A wheel bearing was replaced along with a few other items and I was told that it was good to go. I…
In march while driving my 2004 chevy 3500 diesel truck the brake warning lights inside the cab lit up and the brake pedal was feeling spongy. I took it into classic auto group mentor for service. A wheel bearing was replaced along with a few other items and I was told that it was good to go. I picked it up. The brake pedal was still spongy and the warning lights were still on. On april 22, I returned to the classic auto group chevy service to again have the brakes serviced. They billed me $1400.00 to change a valve, a module and some screws. the brakes now go all the way down to the floor when depressed with the motor running. There IS no effective braking ability. With no effective braking the warning lights are not lit up. Classic auto group chevy in mentor says that this IS normal. this IS not how the brakes worked before the warning lights came on. They worked like brakes on any vehicle. Classic auto group mentor says that I should just get used to it. I have a complaint number from chevy # [xxx] information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(B)(6). *tr
- Engine
Ticking under hood. Exhaust leak due to broken exhaust manifold bolt passenger side near firewall. Tried to loosen other bolts, 3 more broke. Truck has very low miles, 8.1L motor. Internet shows thousands of same issues. Bolts used are very thin for what they do. *tr
- Fuel system, gasoline
2004 chevrolet silverado 3500. consumer writes in regards to engine injectors issue. *smd the consumer stated the injectors were replaced in 2010, and now then need to be replaced again.
- Service brakes
I was coming home from work this evening and was pulling up to the garage and the brakes failed causing me to hit the garage. I was traveling less than 5 mph. The brake pedal went all the way to the floor and the vehicle would not stop. After getting out of the vehicle found brake fluid all over…
I was coming home from work this evening and was pulling up to the garage and the brakes failed causing me to hit the garage. I was traveling less than 5 mph. The brake pedal went all the way to the floor and the vehicle would not stop. After getting out of the vehicle found brake fluid all over the driveway. Brake lines was found to be rusted in two in several places after having a friend who IS a mechanic come and look at vehicle. he found a couple lines that had exploded thru right under the drivers side seat on top the frame and another one above the fuel tank. After googling what had happened there thousands of complaints with nhtsa on this problem with gm vehicles. Why are we paying you people to try and keep the public safe. This IS a very ongoing problem with gm vehicles and needs addressed promptly. *jb
- Service brakes
Had just hooked up our 38' - 12,000lb fifth wheel and headed out for the weekend. Came to the first stop sign and the brake pedal went to the floor. Luckily got stopped with trailer brakes. After stopping, pumping brakes caused brake fluid to pour out from just in front of the driver's side rear wheel. Upon research when we arrived home, I find that this IS an ongoing issue with chevrolet trucks.
- Service brakes
Brakes failed. china made steel brake lines rusted out and disintegrated. could have been killed. had to get repair to steel brake lines from ABS pump to master cylinder and front calipers. also make up and replace steel brake line to rear axle and to rear left and right rear calipers. also had to replace bleed screws in all calipers. *tr
- Service brakes
While driving my chevy silverado 3500 dually at approximately 50 mph, I had so make a sudden emergency stop. my brake pedal went to the floor with virtually no stopping power for the vehicle. I swerved out of the way to avoid an accident and was very lucky. the truck went directly to the repair…
While driving my chevy silverado 3500 dually at approximately 50 mph, I had so make a sudden emergency stop. my brake pedal went to the floor with virtually no stopping power for the vehicle. I swerved out of the way to avoid an accident and was very lucky. the truck went directly to the repair shop which has informed me that the brake lines are rusted through and all need to be changed. I called the chevy support number to report this problem and ask about a recall. the rep took the last eight of my vin number and said there IS no known problem with the brakes on this vehicle. I tow heavy equipment with this truck for work, so it IS an alarming safety concern for me for the brakes to suddenly not work without warning. I am lucky that nobody got killed due to this problem. *tr
- Service brakes
County road (thank goodness). driving about 45 mph when a lady turned off a side road in front of me. I stepped on the brake pedal to avoid a rear end collision. The brake pedal held momentarily but then went to the floor. I swerved right into the ditch and used the emergency brake to keep from…
County road (thank goodness). driving about 45 mph when a lady turned off a side road in front of me. I stepped on the brake pedal to avoid a rear end collision. The brake pedal held momentarily but then went to the floor. I swerved right into the ditch and used the emergency brake to keep from striking her car in the rear. in order to get the vehicle home (approximately 3 miles), I had to use the emergency brake to stop. could not afford to get the truck to the dealership (approximately 15 miles away in heavy suburban traffic) for diagnosis and repair. Saved up and took the truck to a local mechanic (09/2012). Mechanic ask if the truck had ever been under water. Reason for question was the brake lines, front calipers, and top forward frame were severely rusted. The brake lines rusted through causing a break failure. this truck has less than 21,000 miles, never been submerged in water, occasionally driven in the winter, washed frequently (especially in the winter) and waxed, and has zero body or bed rust. after repair, the ABS light came on and stays on. I read somewhere on this site a bulletin regarding premature ABS sensor failure and dealers fixing the sensors but I can not find the ABS bulletin now. *tr
- Unknown or other
2004 chevrolet silverado 3500. Attorney writes on behalf of clients in regards to negligent driver collision *tgw the attorney stated the driver of a tractor trailer, drove off the emergency lane into his clients lane of travel resulting in a very severe collision, because his client was unable to…
2004 chevrolet silverado 3500. Attorney writes on behalf of clients in regards to negligent driver collision *tgw the attorney stated the driver of a tractor trailer, drove off the emergency lane into his clients lane of travel resulting in a very severe collision, because his client was unable to avoid running into the rear of his tractor trailer. The attorney believed the driver was talking on his cell phone and was improperly located in the emergency lane and did not signal that he was about to enter back into the lane of travel. as a direct and proximate result, his clients suffered significant injuries. *Jb
- Engine
In january 2004, I bought a new chevy 3500 duramax diesel truck. since march 2005, I have had to have the injectors replaced a total of 6 times. now at 202,000 the injectors need replaced again. chevy will not help out on this problem. I have read that everyone should file a complaint with this…
In january 2004, I bought a new chevy 3500 duramax diesel truck. since march 2005, I have had to have the injectors replaced a total of 6 times. now at 202,000 the injectors need replaced again. chevy will not help out on this problem. I have read that everyone should file a complaint with this department so that this can be investigated. in november 2011, someone was told there were not complaints. being a chevy owner with these injector problems, I am writing to complain. hopefully, this department will conduct the investigation and help all the other people with this problem get a response from chevy to do something. These trucks are not cheap and just because we use our trucks and put miles on them, and they have repeated failures, we should not have to bear the burden. this problem with my truck IS in the design. how many people replace injectors every 30-40k miles? this IS what I have had to do over the last 7 years. *tr
- Service brakes, hydraulic
Brake line rusted and failed while driving. heavy rust on several brake lines, frame, and cross members. *tr
- Fuel system, diesel
Chevy silverado 3500 duramax diesel, has a cracked fuel filter housing, contacted chevy/gm customer care regarding this problem and even gave them a tsb that I found on website and informed them of many complaints from other owners. they refuse to repair the fuel filter housing at their, when I…
Chevy silverado 3500 duramax diesel, has a cracked fuel filter housing, contacted chevy/gm customer care regarding this problem and even gave them a tsb that I found on website and informed them of many complaints from other owners. they refuse to repair the fuel filter housing at their, when I took vehicle in to be checked out it states that this needs to be repaired and could be a safety hazard as fuel can leak into housing and catch fire. I told the customer care agent of my concern about the safety of this issue and was told that gm/chevy would not pay for it! I have had major issues with this vehicle for over six months and gm refuses to assist me with most of my concerns. *tr
- Service brakes, hydraulic
Brake lines rusted through casing brake failure and a crash. No warning light. *tr
- Service brakes, hydraulic
Slowing down to turn into a shopping center when the brake pedal went to the floor. I was not yet committed to the turn lane so I was able to pass the entrance and stop on the side of the road .this IS the second failure the first one occurred less than 1000 miles before on 5/23/11 odi #10402905…
Slowing down to turn into a shopping center when the brake pedal went to the floor. I was not yet committed to the turn lane so I was able to pass the entrance and stop on the side of the road .this IS the second failure the first one occurred less than 1000 miles before on 5/23/11 odi #10402905 .the service tech says the line don't look that bad ,and he could not buy replacement lines from chevrolet. I have been lucky twice! *kb
- Fuel system, diesel
TL* the contact owns a 2004 chevrolet silverado 3500. The contact stated that the vehicle was stopped with the brakes engaged when she noticed black and white smoke coming from the muffler. The failure continued whenever the vehicle was operated. The vehicle was taken to an authorized dealer where…
TL* the contact owns a 2004 chevrolet silverado 3500. The contact stated that the vehicle was stopped with the brakes engaged when she noticed black and white smoke coming from the muffler. The failure continued whenever the vehicle was operated. The vehicle was taken to an authorized dealer where the contact was informed that three of the eight injectors failed. The vehicle was not repaired. The failure mileage was unknown and the current mileage was 60,000. updated 07/26/11 *bf the consumer stated three injectors failed. Updated 07/28/11
- Service brakes, hydraulic
TL* the contact owns a 2004 chevrolet silverado 3500. The contact was driving 70 mph when he applied the brakes and heard a loud scraping noise. The vehicle was taken to an authorized dealer where the contact was informed that all four brake pads and rotors needed to be replaced. The brake pads and rotors were replaced. The failure mileage was 39,620.
- Service brakes, hydraulic
I was unloading mulch from the bed of truck onto the flower beds in my yard. When I got back into the truck to move to a new spot everything was fine until I went to stop and the brake pedal went to the floor. The truck was only at an idle but the brake wouldn't even slow it down to a walking…
I was unloading mulch from the bed of truck onto the flower beds in my yard. When I got back into the truck to move to a new spot everything was fine until I went to stop and the brake pedal went to the floor. The truck was only at an idle but the brake wouldn't even slow it down to a walking speed. the parking brake worked fine and the truck came to a stop. I put the rest of the mulching job on hold until the next day until I could figure out what had just happened and how to deal with it. the next day I checked the brake fluid and added almost a quart. when I went to move the truck the brake still went to the floor but I was ready for that and got the truck off of the grass and back out onto the driveway. that was when I saw just how bad it was leaking brake fluid and the truck IS still here at my house. I guess I will have it towed somewhere to have the brake line that runs down the left side of the truck to the rear wheels replaced. *tr
- Service brakes, hydraulic
Brake lines, transmission lines and engine coolant lines all failing on 2004 chevy silverado 3500 HD as well as on 2003 GMC sierra 2500 HD. these problems have caused numerous amounts of time to repair and replafe, and today there was a brake failuer on the 2004 HD GMC that almost resulted in…
Brake lines, transmission lines and engine coolant lines all failing on 2004 chevy silverado 3500 HD as well as on 2003 GMC sierra 2500 HD. these problems have caused numerous amounts of time to repair and replafe, and today there was a brake failuer on the 2004 HD GMC that almost resulted in deadly accident. these lines should not have rusted and we have issues with both vehicles on the same lines. these vehicles were producted with inadequate parts for all lines on the underside of vehicle. there should not be 1,000 plus complaints from consumers regarding the rusting of these components, of which have cuased several major anmd life safety issues. the brake lines are an integral part of any vehicle and to have them rust thru to the degree of all the complaints there IS obviously an issue with the compenents the manufacturer installed on these vehicles. between our 2004 chevy and 2003 GMC trucks we have replaced all of the tranmission collant lines, oil engine lines and ready to change brake lines in 1 truck with the other truck having to also be replaced due to rust. the entire underside compenents are completely rusted through. *tr
- Engine and engine cooling › Exhaust system
Broken exhaust manifold bolts 2004 6.0 chevy silverado 3500 29000 miles. *Tr
- Service brakes, hydraulic
Tl*the contact owns a 2004 chevrolet silverado 3500. He had to increase stopping distance when braking. While driving he also experienced a loss of power steering. Upon further inspection he noticed that the hydro-booster pump leaked brake and steering fluid. He notified the manufacturer in…
Tl*the contact owns a 2004 chevrolet silverado 3500. He had to increase stopping distance when braking. While driving he also experienced a loss of power steering. Upon further inspection he noticed that the hydro-booster pump leaked brake and steering fluid. He notified the manufacturer in reference to recall# 05v043000 (service brakes). A representative stated that since his vehicle identification number was excluded from the recall, he would have to pay $1,000.00 for repairs. The vehicle identification number was unavailable. No repairs were made. The failure and current mileages were 180,000.
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 11010544This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.
- 11007208This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed for the vehicle in question and its applications. Technician should not use the information that is provided by the antilock braking system tire size selection.
- 11006621Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected modules (with some exceptions). The updating of modules is completed in parallel instead of the technician needing to update one module at a time. This allows a more streamlined approach for dealers and customers.
- 11006421GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the dealers to be more careful not to damage the transmissions during removal and to package the core properly for return.
- 11004761This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up.
- 11004557This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim.
- 11002312This service bulletin provides information for dealers/technicians on Service Programming System (SPS) Error Codes E4398, E4399, E4401, E4403, M4404, M4413, M6954, M6955, E4414, E4423, E4491, E4492, or E6961 and resolution information.
- 11000576This Warranty Administration bulletin provides retail and wholesale service personnel with the policies/procedures and the warranty transaction submission procedures that support the Personal Property Damage process.
- 10252735This bulletin provides information for electrical ground repairs using new General Motors replacement fasteners with conductive finish.
- 10252163XM Audio Traffic And Travel Link Availability And Operation.
- 10251890This technical bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up.
- 10251887This bulletin advises the technician of possible location of an internal coolant leak from a specific cylinder head and location.
- 10250775This service bulletin provides service information to technicians on guidelines to replace Oil Cooler, Oil Cooler Lines and Oil Tank if the engine was replaced where large amounts of debris has flowed throughout the oiling system.
- 10249980This Preliminary Information communication provides information to the technician about vibration complaints that are one of the most challenging complaints to accurately diagnose and repair. Technician will need to use Pico Oscilloscope Diagnostic Kit to effectively diagnosis vehicles. Technician should drive the vehicle will using the Pico Oscilloscope to record data. After the data is recorded it should be reviewed to determine the root cause of the concern. If a repair attempt made the concern better but not eliminated or had no affect at all, and are requesting assistance from General Motors Technical Assistance Center record another Pico file and save it to the computer. After the new Pico Oscilloscope data has been saved email the data to General Motors Technical Assistance Center in the subject line include ?Vibration? ?Business Associate Code? and the last 8 of the Vehicle Identification Number.
- 10249590This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim.
- 10249579This PI bulletin advises the technician on the proper way to install the pistons in an engine.
- 10249011This informational bulletin provides information for dealers/technicians on Headlamp, Tail Lamp, License Lamp or Fog/Driving Lamp Damage.
- 10248444Vehicle Recalls
- 10247780This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature.
- 10247748Speedometer Needle Accuracy Information.
- 10247747Speedometer Needle Accuracy Information
- 10247681Information On Requests To Add OnStar Bluetooth Option.
- 10247552This service bulletin provides information on Concerns or Questions Regarding Installation of Dealer Installed Accessories.
- 10247093Speedometer Needle Accuracy Information.
- 10247092Speedometer Needle Accuracy Information
- 10246952Programming And Activation Of Replacement OnStar Modules.
- 10246951Programming And Activation Of Replacement OnStar Modules.
- 10246647Pre-Formed and Pre-Flared Hydraulic Brake Pipe Kits Now Available for Service
- 10246646Pre-Formed and Pre-Flared Hydraulic Brake Pipe Kits Now Available for Service
- 10246645Pre-Formed and Pre-Flared Hydraulic Brake Pipe Kits Now Available for Service
- 10246631Expanded Availability for Remanufacture and Return (R&R) Electronic Control Modules
- 10246624Car and Truck Fix it Right the First Time Issues
- 10246499Duramax Diesel Glow Plugs Difficult to Install Due to Carbon Buildup - New Glow Plug Bore Reamer Available
- 10245951Canadian Customers Unable To Place Calls And Turn By Turn Inoperative In The United States.
- 10245950Canadian Customers Unable To Place Calls In The United States
- 10245395This service bulletin provides a vibration analysis worksheet the technician can use in conjunction with the appropriate Vibration Analysis-Road testing procedure when diagnosing vibration concerns.
- 10244274This service bulletin provides information about the Hunter wheel Road Force balancers that should be utilized for all repairs requiring balance and Road Force measurement.
- 10244214This informational bulletin provides information for the IPC odometer programming method quick reference guide.
- 10244201This service bulletin provides information for dealers on how to submit a product information report (PIR) (Canada Only).
- 10242843The service bulletin advises the tech of a normal transmission shift condition and the delay in throttle response when the throttle plate is opened rapidly and advises the customer that it is normal for the delay.
Every Chevrolet Silverado 3500 model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.