2004 Chevrolet Suburban
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Chevrolet › Suburban › 2004
These records cover every 2004 Chevrolet Suburban. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
6 recalls name the 2004 Chevrolet Suburban. Newest first.
On certain trucks equipped with an 8.1L V8 (rpo l8-vin g) engine have a condition in which the engine fuel rail pulse damper retainer clip may fracture resulting in inadequate retention of the damper.
Risk and remedy
Risk
If the damper comes loose, a fuel leak may result. fuel leakage, in the presence of an ignition source, could result in a fire.
Remedy
Dealers will replace the engine fuel rail pulse damper retainer clip free of charge. the recall began on august 31, 2006. owners may contact chevrolet at 1-800-630-2438 and GMC trucks at 1-866-996-9463.
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).
Certain pro-a motors corner lamps, turn signals, and headlights sold as replacement lamps for use on certain passenger vehicles listed above. some combination lamps that are not equipped with amber side reflectors fail to conform to federal motor vehicle safety standard no. 108, lamps, reflective devices, and associated equipment.
Risk and remedy
Risk
Without the amber reflectors, the vehicle will be poorly illuminated, possibly resulting in a vehicle crash without warning.
Remedy
Pro-a motors will notify owners and offer to repurchase the lamps. the recall began on april 3, 2006. owners may contact pro-a motors at 323-838-2988.
On certain crew cab pickup trucks and sport utility vehicles, the 2ND row center occupant seat belt routing may make it difficult to position the lap portion of the safety belt low around the hips of occupants, especially smaller occupants, seated in this position. appropriate use of a child seat or booster seat, as recommended for small children, does…
Risk and remedy
Risk
A lap portion of the seat belt routing that IS not low and snug on the hips can allow the lap belt to ride up on an occupant's abdomen instead of fitting low around their hipbones, and therefore, can expose them to more risk of abdominal and internal organ injury.
Remedy
Dealers will cut open the guide loop, remove a portion of the loop, and then the remaining two sides should be folded over and secured with a retainer free of charge. the recall began on july 21, 2005. owners may contact cadillac at 1-866-982-2339, chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, or hummer at 1-800-732-5493.
Certain trucks, sport utility vehicles, and vans equipped with bosch hydro-boost brake assemblies, the hydraulic brake booster pressure accumulator may crack and separate from the hydro-boost assembly during normal operating conditions.
Risk and remedy
Risk
If a separation occurred and the hood of the vehicle were open, fragments from the accumulator could cause injury to people in the immediate area. the presence of this crack or fractured surface could allow the hydraulic fluid to leak from the accumulator circuit of the booster assembly. the loss of fluid would cause increased steering and braking effort and a crash may occur without prior warning.
Remedy
Dealers will test the hydro-boost assembly for functional operation of the two-function valve. if the hydro-boost assembly fails the test, dealers will replace the assembly free of charge. The recall began on march 23, 2005. owners may contact chevrolet at 1-800-630-2438, GMC trucks at 1-866-996-9463 and hummer at 1-800-732-5493.
Certain sport utility vehicles, pickup trucks, and passenger vans fail to comply with the requirements of federal motor vehicle safety standard no. 135, ?passenger car brake systems.? some of these vehicles were produced with an out-of-specification brake hydro-boost housing relief valve bore.
Risk and remedy
Risk
Consequently, the valve o-ring seal may fracture. steering efforts may be slightly increased while braking or parking. under certain driving conditions, a fractured seal may require a slight increase in the applied brake pedal effort to achieve the same vehicle deceleration rate as prior to the seat fracture.
Remedy
Dealers are to replace the hydro-boost relief valve. the recall began on june 18, 2004. owners should contact cadillac at 1-866-982-2339; chevrolet at 1-800-630-2438; GMC at 1-866-996-9463; or hummer at 1-866-486-6376.
Owner complaints
204 complaints12 involved a crash6 involved a fire10 injuries
What owners report most
Latest complaints
- Air bags
Front passenger dash airbag spontaneously deployed without any inciting event. The vehicle is at the Team Chevrolet Goldsboro dealership. A case has been opened with General Motors Case Number XXX. No prior warning - it smoked for a few seconds then deployed. No prior warning lights.
- Electrical system › Instrument cluster/panel
The contact owns a 2004 Chevrolet Suburban. The contact stated that while driving at an undisclosed speed at night, the instrument panel gauges, and warning lights functionality became inoperable. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 150,000.
- Air bags · Engine and engine cooling
The contact owns a 2004 Chevrolet Suburban. The contact stated that while driving approximately 45 mph he noticed the temperature gauge increased to the high indicator. The engine coolant hot message was displayed. The contact stated that while attempting to pull over there was an abnormal popping…
The contact owns a 2004 Chevrolet Suburban. The contact stated that while driving approximately 45 mph he noticed the temperature gauge increased to the high indicator. The engine coolant hot message was displayed. The contact stated that while attempting to pull over there was an abnormal popping noise and smoke was detected. The air bag warning light illuminated and the driver's side air bag deployed without impact or crash and struck the driver in the face, chest, and right hand. There was no medical attention provided, or a fire or police report filed. The vehicle was left on the side of the road. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 200,000.
- Electrical system · Service brakes · Steering
Brake/abs light on and ecbm for abs not working no anti lock brake system and for the electrical vehicle has all kinds of electrical issues had to remove fuse to radio because of it going bonkers and it wouldn't turn off or down sounds like a fax machine or old school dial up internet sounds all…
Brake/abs light on and ecbm for abs not working no anti lock brake system and for the electrical vehicle has all kinds of electrical issues had to remove fuse to radio because of it going bonkers and it wouldn't turn off or down sounds like a fax machine or old school dial up internet sounds all the time and siren sounds were coming from radio and speakers only way to make it stop was to pull the fuse and have had to get multiple four wheel alignments because of steering and steering has to much play in it before suburban turns
- Structure › Body · Suspension
TL* the contact owns a 2004 chevrolet suburban. The contact stated that while shifting gears, there was an abnormal clunking sound coming from underneath the vehicle. There were no warning lights illuminated. The vehicle was taken to an independent mechanic where there were unable to determine the…
TL* the contact owns a 2004 chevrolet suburban. The contact stated that while shifting gears, there was an abnormal clunking sound coming from underneath the vehicle. There were no warning lights illuminated. The vehicle was taken to an independent mechanic where there were unable to determine the cause of the failure. The local dealer was not contacted. The vehicle was not diagnosed nor repaired. The manufacturer was not notified of the failure. The failure mileage was 238,239.
- Electronic stability control (esc) · Service brakes · Steering
The hydro booster IS defective. The car triggers my breaks and makes noises make steering braking difficult. It happens everyfay throught the day while im driving
- Service brakes
ABS breaks kicking in at low speed and not stopping almost wrecked several times
- Visibility/wiper
Rear tailgate glass has separated from the glued on hinges and dropped down on the drivers side. This appears to be an ongoing design, quality issue and has happened on a large number of SUV style chevrolet vehicles as can be seen using a simple internet search concerning this issue.
- Air bags
TL* the contact owns a 2004 chevrolet suburban. While the vehicle was in motion, the driver's side air bag deployed with force. A yellow substance emitted inside the vehicle when the failure occurred. The deployment occurred without warning or an impact. There were no injuries. A police report was…
TL* the contact owns a 2004 chevrolet suburban. While the vehicle was in motion, the driver's side air bag deployed with force. A yellow substance emitted inside the vehicle when the failure occurred. The deployment occurred without warning or an impact. There were no injuries. A police report was filed. The manufacturer was not notified. The vehicle was not diagnosed or repaired. The approximate failure mileage was 128,000.
- Service brakes
TL* the contact owns a 2004 chevrolet suburban. The contact stated that the vehicle was experiencing the same failure as listed in nhtsa campaign number: 04v045000 (service brakes, hydraulic). There were no warning indicators illuminated. An independent mechanic diagnosed that the brake booster…
TL* the contact owns a 2004 chevrolet suburban. The contact stated that the vehicle was experiencing the same failure as listed in nhtsa campaign number: 04v045000 (service brakes, hydraulic). There were no warning indicators illuminated. An independent mechanic diagnosed that the brake booster system needed to be repaired. The vehicle was not repaired. The manufacturer and dealer were not made aware of the failure. The failure mileage was 192,000.
- Electrical system
The truck fails to restart after driving it an at first it would restart after 15 - 20 minutes after it sits an now it does not start at all so far I know it IS happening to more than 20 vehicles including the state patrol 2016 suburbans and several of the pickups
- Unknown or other
Cracked dash, never removed, garage kept. Cracked runs through dash from front window towards radio cluster. Dash has sharp pieces that in accident can easily be broken off.
- Fuel/propulsion system
The exhaust manifold bolts have snapped off, 4 of them to be exact. Exhaust fumes can now leak into to the cab and poison occupants.
- Electrical system · Power train
Instrument cluster shorts out and gear indicator goes blank. No message center information warnings are displayed. Part IS defective and car makers should replace it. Not knowing what gear vehicle IS in can lead to death if vehicle left in neutral and rolls away. Gm needs to fix this expensive…
Instrument cluster shorts out and gear indicator goes blank. No message center information warnings are displayed. Part IS defective and car makers should replace it. Not knowing what gear vehicle IS in can lead to death if vehicle left in neutral and rolls away. Gm needs to fix this expensive problem. Also 4l60e transmission on these vehicles fails and starts slipping because of defective sun shell and real piston seal. Gm should recall all these bad transmissions. Warranty should have been for life. Why should such an expensive part to repair fail under normal use? Recall ! both these parts fail when driving. All warning of vehicle conditions are sent to failed cluster. Vehicle was made in mexico for re-importation and sale in USA and maybe parts suppliers in mexico provided defective parts. Many people have suffered financial loss trying to fix these problems, lastly, the emission solenoid near the tank also fails. Vehicle may not pass emission. *tr
- Service brakes
While avoiding another vehicle I applied my brakes suddenly. The bake like connecting the ABS unit and the rear brakes failed due to corrosion/rust that was not observable due to the line being ran between the vehicles frame and body and gas tank. Although this location might have made for easy…
While avoiding another vehicle I applied my brakes suddenly. The bake like connecting the ABS unit and the rear brakes failed due to corrosion/rust that was not observable due to the line being ran between the vehicles frame and body and gas tank. Although this location might have made for easy manufacturing it has led to the line being in a location that cannot be visually inspected to prevent dangerous conditions from building up from lack of awareness. .
- Electronic stability control (esc) · Service brakes
Total brake failure (vehicle has 95,387) miles) at 40 mph in motion. stabil-trac light indicated at the time of failure, service brake indicator on display information console. . Deployed 4WD low, dropped to lower gear and hit emergency brake to stop the vehicle on shoulder of road. Got out of…
Total brake failure (vehicle has 95,387) miles) at 40 mph in motion. stabil-trac light indicated at the time of failure, service brake indicator on display information console. . Deployed 4WD low, dropped to lower gear and hit emergency brake to stop the vehicle on shoulder of road. Got out of vehicle saw brake fluid all over the skids and frame. Cause: towed to local shop indicated that brake lines on driver side and lines going to front wheel were completely rusty and "like paper". this was unsettling I don't live near saltwater but drive the vehicle a lot in winter. had I been in a densely populated area, there certainly would have been loss of life. this vehicle weighs over 6000 lbs and no brakes IS like to trying to stop a train. please investigate similar failures as this failure in similar vehicles/any vehicle could cause loss of life.
- Service brakes
2004 chevy suburban - sudden & complete loss of brake pressure at highway speed. Vehicle brakes were inspected in july through the va state inspection program - no issues found - today on 8/30/16 while exiting a freeway ramp at 60mph traffic came to sudden stop. When the service brake was applied…
2004 chevy suburban - sudden & complete loss of brake pressure at highway speed. Vehicle brakes were inspected in july through the va state inspection program - no issues found - today on 8/30/16 while exiting a freeway ramp at 60mph traffic came to sudden stop. When the service brake was applied in what would be considered a stab/emergency braking maneuver there was a complete and sudden loss of brake pressure - pedal went to floor without warning, brake would not pump up adequate enough to slow vehicle. I had to use a combination of parking brake application and utilizing the soft shoulder and ditch to stop the vehicle. The brake warning indicator (red) and service indicator did not illuminate until after the third or fourth application of the brake pedal. Suburban was towed. Causative factors = ruptured brake line.
- Service brakes
Brake line (hard line) catastrophic failure. Unable to stop on coming to highway intersection using hydraulic brakes. Had to resort to applying parking brake to stop vehicle. On inspection main brake hydraulic line ruptured- fluid spewed on roadway and approximately 1/2 of fluid from master cylinder. Limited residual pressure from secondary was unable to stop vehicle without mechanical assist from parking brake.
- Power train
TL* the contact owns a 2004 chevrolet suburban. While the vehicle was in the park position, the gear shifted into the neutral position unexpectedly without warning. The failure occurred once. The vehicle was not diagnosed nor repaired. The manufacturer was notified of the failure. The failure mileage was 148,000.
- Service brakes
Driving as normal attempt to stop and pedal went to the floor. no brakes. coasted to stop luckily not traveling at high speed. inspection revealed rusted through brake lines. And all fluid gone from master cylinder.
- Service brakes
TL* the contact owns a 2004 chevrolet suburban. While driving 25 mph, the brake pedal was depressed and the brakes seized. The service brakes warning indicator illuminated after the brake failure. The contact stated that the emergency brake was engaged in order to stop the vehicle. The contact also…
TL* the contact owns a 2004 chevrolet suburban. While driving 25 mph, the brake pedal was depressed and the brakes seized. The service brakes warning indicator illuminated after the brake failure. The contact stated that the emergency brake was engaged in order to stop the vehicle. The contact also stated that brake fluid was leaking under the vehicle. The vehicle was towed to an independent mechanic where it was diagnosed that the brake lines failed due to corrosion and needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was 114,000.
- Service brakes
Brake line failed while towing boat on city street normal braking lost 3/4 braking power, pedal went almost to the floor, just stopped in time before rear ended someone.
- Service brakes
TL* the contact owns a 2004 chevrolet suburban. While driving at approximately 55 mph, the brakes did not engage when the brake pedal was depressed. The contact was able to pull over to the road side. the vehicle was towed to an independent mechanic where it was diagnosed that front brake lines…
TL* the contact owns a 2004 chevrolet suburban. While driving at approximately 55 mph, the brakes did not engage when the brake pedal was depressed. The contact was able to pull over to the road side. the vehicle was towed to an independent mechanic where it was diagnosed that front brake lines were corroded and needed to be replaced. The vehicle was repaired. The manufacturer was made aware of the failure. The approximate failure mileage was 170,000. The vin was not available.
- Service brakes
Backing out of a parking space went to stop and brake pedal sunk to the floor ABS and brake light came on I put the truck in park opened the hood the master cylinder had fluid then looked under the truck and under the drivers side door brake fluid was leaking from 1 of the 2 steel rusted lines had…
Backing out of a parking space went to stop and brake pedal sunk to the floor ABS and brake light came on I put the truck in park opened the hood the master cylinder had fluid then looked under the truck and under the drivers side door brake fluid was leaking from 1 of the 2 steel rusted lines had the truck towed to a repair shop the shop said the 2 lines from the master cylinder to the ABS block had severe corrosion and the rest of the brake lines aren't much better im sorry guys but this IS a serious problem to me I could have been killed or killed someone else im one of the lucky ones I guess so now the truck IS in the shop having all the brake lines changed for a cost of $ 600.00 and guess what we also own a 2003 tahoe with 90000 miles on it I guess they will have to be changed also same condition all brake lines rusted badly how many people must be seriously injured or killed before something IS done about this problem its wide spread look on line how many people have gone through this its a shame make g.m do the right thing here
- Air bags
TL* the contact owns a 2004 chevrolet suburban. After turning the ignition key to start the engine, both the driver and passenger side air bags erroneously deployed. During the incident, the driver sustained chest and facial bruises and lacerations. The front passenger sustained bruises and…
TL* the contact owns a 2004 chevrolet suburban. After turning the ignition key to start the engine, both the driver and passenger side air bags erroneously deployed. During the incident, the driver sustained chest and facial bruises and lacerations. The front passenger sustained bruises and lacerations to both arms and hands. Medical attention was not received. The cause of the failure was not diagnosed. The manufacturer was notified of the failure. The failure mileage was 160,000.
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Hydraulic pump failres
Gm IS conducting a recall on all subject vehicles build between may 1999 and october 14, 1999.significant changes were incorporated into production in early october 1999, and vehicles built after that date have lower warranty failure rates.the complaint and warranty data appear to support the effectiveness of these…
Gm IS conducting a recall on all subject vehicles build between may 1999 and october 14, 1999.significant changes were incorporated into production in early october 1999, and vehicles built after that date have lower warranty failure rates.the complaint and warranty data appear to support the effectiveness of these changes. Gm made additional changes in november 1999, february 2000, may 2001, and february 2004.odi will continue to monitor this problem and will take further action, if warranted, in the future.for further technical details see the attached engineering analysis report.
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.
- 11009156This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester and Vehicle Data Recorder tools, giving website address and step by step instructions to complete the update.
- 11007744This 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.
- 11007743This 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.
- 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.
- 11006274This Preliminary Information communication provides information to the technician about vehicles that the speedometer needle appears to be inaccurate. Dealer should advise the customer the specification for speedometer needle accuracy is +/- 2 MPH at any given speed when looking straight at the needle.
- 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
- 10247693Suspension.
- 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
- 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.
Every Chevrolet Suburban model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.