2004 GMC Sierra 3500
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › GMC › Sierra 3500 › 2004
These records cover every 2004 GMC Sierra 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 GMC Sierra 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
24 complaints2 involved a fire
What owners report most
Latest complaints
- Electrical system
The fan for the heater doesnt work on all speeds properly, stopped working entirely
- Service brakes
While pulling a camper-trailer, I applied the brakes and the pedal went completely to the floor. I was able to stop utilizing the brakes on the trailer. I was only a short distance from home and I was able to get the trailer back, keeping the transmission in 1ST gear and the trailer brakes. I…
While pulling a camper-trailer, I applied the brakes and the pedal went completely to the floor. I was able to stop utilizing the brakes on the trailer. I was only a short distance from home and I was able to get the trailer back, keeping the transmission in 1ST gear and the trailer brakes. I took the truck to a chevy dealer that was just a very short distance utilizing the gears and the emergency brake. upon inspection, the dealer found at least two locations where the brake line had rusted through. he recommended to replace all brake lines with a line that was corrosion resistant. the repair was just under $2000. I have not contacted GMC since the truck has 74,000 miles and IS out of all warranties. *tr
- Service brakes
I was traveling on the interstate towing a 5TH wheel trailer and traffic came to an abrupt stop. I applied my brakes and had brakes than the pedal went to the floor and I lost braking power. I let off the brakes and reapplied the brakes and the pedal went to the floor with low breaking affect. I…
I was traveling on the interstate towing a 5TH wheel trailer and traffic came to an abrupt stop. I applied my brakes and had brakes than the pedal went to the floor and I lost braking power. I let off the brakes and reapplied the brakes and the pedal went to the floor with low breaking affect. I pulled the truck over and found brake fluid coming out from above the gas tank. I carefully took the truck off at the next exit using my trailer brakes to stop the vehicle. I took the truck to the first service station that I saw and had them look at it. They found that the rear brake line had corroded at a clip above the frame rail above the gas tank and advised me that they would have to replace the rear brake line. Unfortunately I was stuck away from my tools and service shops that I use and was stuck being gouged by the service center that I was able to get to for a repair. After I returned home from vacation I questioned the mgt of the service center about the bill. They checked with the local dealer about the hours for the repair and the local dealer advised them that they see this all the time on this vehicle. I looked for a recall on this and found none. I contacted gm about this as just about everyone that I talk to about this problem has all seen it. Gm advised me that it was an isolated problem and that they could not help with the repair since the truck was 9 years old. I advised them that this IS a common problem and they deny it but they did offer me $2000 towards a new gm vehicle. I advised them that was not what I was after as I do not need a new vehicle nor want an new vehicle. What I did ask for was 50% of what the repair was as it was a 9 year old truck and they refused. They will not even put the refusal in writing. This needs to be a recall before this problem kills someone as it IS a common problem. I seen an investigation to 03 but mine IS 04 with same. *tr
- Service brakes
Brake line rusted out and failed in two spots in the last month. *tr
- Service brakes
This past week, as I was driving to get gas for our camping trip, the brake pedal went straight to the floor with no warning. I was able to get the dually slowed down without incident, but was it ever close. after getting the truck back to my house, I began investigating the issue as I saw no…
This past week, as I was driving to get gas for our camping trip, the brake pedal went straight to the floor with no warning. I was able to get the dually slowed down without incident, but was it ever close. after getting the truck back to my house, I began investigating the issue as I saw no leak and the reservoir was near full. I saw online that this seems to be a gm issue with a few years of trucks in my age bracket. I climbed up under the truck and found the lines to be shot. not one with a rust hole, but all of them corroded from one end to the other. I know the truck IS 8 years old, but it sits most the time and almost always through the winter. I have only had one other car in 30 years that had a brake line rust. it should not be happening in this high end of a vehicle. my dad bought the matching truck. his sits winters in the barn and only has 50K on it. I will check it this weekend. *js
- Service brakes
Brakes failed due to a sudden brake line failure. There had been no prior fluid leaks. The rear metal brake line under the bed rusted at a clamp in front of the fuel tank. As I have looked further into this I have several friends that have had this problem and several shops said that they saw this often with these vehicles all failing in the same area. *tr
- Service brakes
I picked my stepdaughter at school and at the stoplight to leave the school there were no brakes. I used the curb to slow the truck enough to the lights to change. it was not a busy time and students were not present otherwise this would have been a disaster. I drove the truck home with…
I picked my stepdaughter at school and at the stoplight to leave the school there were no brakes. I used the curb to slow the truck enough to the lights to change. it was not a busy time and students were not present otherwise this would have been a disaster. I drove the truck home with flashers very slowly home on a back road downshifting and relying in the allison transmission. when I reached home the light came on to service brakes. that was obvious already. this IS a 1 ton dually that usually hauls skid loads, paving bricks, etc. I could not imagine what would have happened if the brake lines blew during this time. there IS a small rusted pin sized whole in the front brake line that runs on top of the truck frame. I still have brake fluid in the reservoir, but not enough to stop the truck. there was not warning and those lines are tucked up on the frame out of site for inspection. this incident went to fine to disaster immediately. what would have happened if this vehicle were traveling at 70 mph and needed to stop? this IS fatality waiting to happen. this size of truck would have killed me and anyone I would have hit at highway speeds. shame on you GMC. brakes and rotors were replaced 4 years ago. emergency brake was repaired by GMC certified shop also 4 years ago due to fact the vacuum plate rusted off. they did not inform me of any issues of brake lines rusting like this otherwise this would have been repaired! *tr
- Service brakes
Approaching a stop. When the brakes were applied, the brake pedal dropped almost completely to the floor and stopping was extremely difficult. Discovered that the brake lines which run along the frame behind the driver side front wheel had corroded to the point where one of the lines failed and…
Approaching a stop. When the brakes were applied, the brake pedal dropped almost completely to the floor and stopping was extremely difficult. Discovered that the brake lines which run along the frame behind the driver side front wheel had corroded to the point where one of the lines failed and blew open. The lines are clamped against the frame in this location, and all the 4 lines at the bracket appear extremely corroded. *tr
- Service brakes
On highway multi-lane, heavy traffic ahead, suddenly slowed and a lot of lane changing going on as some debris was ejected from truck onto roadway. Applied brakes, application had little effect. Stood on the brakes, butt out of the seat standing on the brakes, truck veered off to right severely…
On highway multi-lane, heavy traffic ahead, suddenly slowed and a lot of lane changing going on as some debris was ejected from truck onto roadway. Applied brakes, application had little effect. Stood on the brakes, butt out of the seat standing on the brakes, truck veered off to right severely while ant lock pulsed. Fortunately traffic got out of the way and escaped harm. Exited highway inspected vehicle. Upon exiting the truck found puddle of brake fluid on ground under driver's seat. Brake lines leaking. Sever rust throughout the brake system. Replacement of all brake lines required. This was very close to crash, only the rapid reflexes of the guy next to me averted an accident. Note, repair shop tells me that (and has shown me) all the brake lines must be replaced. As the lines enter a distribution box ( anti-lock anti-skid under the driver's seat) and the clamping devices all had significant rust to the point of failure. *tr
- Service brakes, hydraulic
TL* the contact owns a 2004 GMC sierra 3500. The contact stated that when depressing the brakes it would take longer than normal to stop the vehicle. The vehicle was taken to an independent mechanic who advised him that he needed to replace the disk and rotors. The vehicle was repaired; however…
TL* the contact owns a 2004 GMC sierra 3500. The contact stated that when depressing the brakes it would take longer than normal to stop the vehicle. The vehicle was taken to an independent mechanic who advised him that he needed to replace the disk and rotors. The vehicle was repaired; however, within approximately 20 months the same failure recurred. The manufacturer was notified of the failure and offered no assistance. The failure mileage was approximately 15,000.
- Fuel system, diesel · Service brakes, hydraulic › Foundation components › Hoses, lines/piping, and fittings
TL* the contact owns a 2004 GMC sierra 3500 HD. The contact stated that there was a large puddle of unknown fluids under the vehicle. After inspecting the vehicle, the contact discovered that the fuel line was severely corroded and causing diesel fuel to leak. The vehicle was taken to a dealer…
TL* the contact owns a 2004 GMC sierra 3500 HD. The contact stated that there was a large puddle of unknown fluids under the vehicle. After inspecting the vehicle, the contact discovered that the fuel line was severely corroded and causing diesel fuel to leak. The vehicle was taken to a dealer where they advised the contact that the fuel line needed to be replaced due to the corrosion. The vehicle was not repaired and the manufacturer was not contacted in regards to the failure. The failure mileage was approximately 117,000. updated 02/03/12*lj the consumer stated the vehicle has since been repaired. The brake lines were corroded as well. updated 02/08/12
- Service brakes, hydraulic
Brake failure due to rusted out brake lines, also on-going since truck was new with ABS engaging at slow down due to corroded sensors. *tr
- Fuel system, gasoline
TL* the contact owns a 2004 GMC sierra 3500. While driving approximately 40 mph, the vehicle became resistant to acceleration. The vehicle was then towed to the dealer where the technicians stated that all eight fuel injectors would need to be replaced. The vehicle was repaired. After the repairs…
TL* the contact owns a 2004 GMC sierra 3500. While driving approximately 40 mph, the vehicle became resistant to acceleration. The vehicle was then towed to the dealer where the technicians stated that all eight fuel injectors would need to be replaced. The vehicle was repaired. After the repairs were made, the failure recurred. The contact stated the previous owner of the vehicle experienced the same failure and had the fuel injectors replaced. The vehicle was then traded for another vehicle. the vehicle was not repaired. The approximate failure mileage was 149,411.
- Electrical system
Fuse box under hood caught fire while parked. *tr
- Service brakes, hydraulic · Steering
TL* the contact owns a 2004 GMC pick up 3500. The contact stated that when applying the brake, the pedal fell further into the floorboard than usual and the brake lights failed to illuminate. The vehicle was towed to the dealer for diagnosis where the contact was informed that the retainer chip for…
TL* the contact owns a 2004 GMC pick up 3500. The contact stated that when applying the brake, the pedal fell further into the floorboard than usual and the brake lights failed to illuminate. The vehicle was towed to the dealer for diagnosis where the contact was informed that the retainer chip for the hydro-boost and brake switch was missing at the brake pedal. The dealer replaced the clip and the brake switch was reinstalled. In addition, while test driving the vehicle the dealer advised that the steering wheel was producing an abnormal sound and advised the contact that the lower bearing assembly was worn. The steering was not repaired. The failure and current mileage was 38,338.
- Fuel system, gasoline › Fuel injection system › Injectors
Tl*the contact owns a 2004 GMC sierra dormax diesel (na). the contact stated that the fuel injectors produce white smoke. ocassionally, the vehicle becomes difficult to start. the contact serviced the injectors every 10,000 miles, but the failure IS persistent. the vehicle was taken to the dealer and they kept replacing the injectors, but to no avail. the failure mileage was 30,000.
- Tires › Sidewall
Tl*the contact owns a 2004 GMC sierra 3500. the vehicle has power king towmax tires, size lt235/80r16e. while pulling the trailer at 65 mph, the sidewall on the passenger tire blew out. no repairs have been made. the cause of the failure was unknown. the failure mileage was 600.
- Electrical system
Speedometer erratically shows incorrect speed while driving. sometimes displaying 120mph or 0MPH. very dangerous and should be a mandatory recall checked with dealer and would cost $800.00 to replace bad instrument cluster. only has 73,000 miles. *Tr
- Service brakes, electric
Anti-lock brake sensors on the front of my 2004 GMC 3500 dually diesel were malfunctioning creating extended low speed stops at a stoplight, causing many close calls in rear ending another car. It appears this IS a common problem ( see: http://www.jsonline.com/story/index.aspx?id=358797 ). My state…
Anti-lock brake sensors on the front of my 2004 GMC 3500 dually diesel were malfunctioning creating extended low speed stops at a stoplight, causing many close calls in rear ending another car. It appears this IS a common problem ( see: http://www.jsonline.com/story/index.aspx?id=358797 ). My state IS excluded from any recall and I was charged $440.00 today to fix this. We salt our roads like any other northern state - this IS absurd! *tr
- Service brakes, hydraulic › Power assist · Steering › Hydraulic power assist system
Tl*the contact owns a 2004 GMC sierra 3500. while attempting a turn, the power steering and power brakes failed. a mechanic stated that the power steering shaft snapped and caused the failures. the contact has had the power steering and power brakes replaced on four separate occasions for the same failures. the speed was unknown. the failure mileage was 40,000 and current mileage was 67,000.
- Electrical system › Instrument cluster/panel
Instrument gauges reading erratically, oil pressure,voltmeter, fuel gauge, temperature gauge. *tr
- Electrical system › Instrument cluster/panel
Tl*the contact owns a 2004 GMC sierra 3500. the contact stated that the speedometer stopped working. the warning indicators were that the speedometer displayed faster speeds than what was actually being driven. as a result, the alternator gauge has failed. he took the vehicle to the dealer and…
Tl*the contact owns a 2004 GMC sierra 3500. the contact stated that the speedometer stopped working. the warning indicators were that the speedometer displayed faster speeds than what was actually being driven. as a result, the alternator gauge has failed. he took the vehicle to the dealer and they stated that he would be responsible for the repair costs because the vehicle had over 75,000 miles. the manufacturer sent the contact a letter that stated they were aware of the defect; however, nothing could be done. the estimated repair costs would be $425. the failure mileage was 65,000 and current mileage was 114,000. updated 5/6/08 *cn updated 05/06/08 *tr
- Power train › Driveline › Center support bearing · Power train › Transfer case (4-wheel drive) · Structure › Frame and members › Underbody shields
Reference a GMC 2004 sierra 3500 4 wheel drive pick up truck, 6.6L diesel engine with 6 speed manual transmission. The molded rubber around the driveline center support carrier bearing (part # 12472424) dry rotted causing driveline vibration that, in turn caused the transfer case to fail. the…
Reference a GMC 2004 sierra 3500 4 wheel drive pick up truck, 6.6L diesel engine with 6 speed manual transmission. The molded rubber around the driveline center support carrier bearing (part # 12472424) dry rotted causing driveline vibration that, in turn caused the transfer case to fail. the vibration was slight and not constant, not indicating a major problem. The part in question IS a non-serviceable part, preventive maintenance did not and would not prevent this failure. The transfer case was totally destroyed and was on the verge of total lock up which would have caused the rear wheels to lock up under normal driving conditions. The cost to fix this problem IS over $3000 dollars to have the dealer do the repairs. Since I am a competent mechanic, I inspected and found this problem when I first noticed a slight vibration, most vehicle owners would have driven the truck until the wheels locked up possibly causing a life threatening crash. The part in question IS without a doubt a defective part. It IS made in china. While many parts coming from china today are of sufficient quality, chinese rubber IS substandard and dry rots in about two years under most circumstances. It IS unconscionable for gm to use substandard parts in such critical areas of their vehicles. *tr information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(B)(6).
- Fuel system, diesel
TL*- the contact states that sometime in august of 2006, fuel injected number 8 failed in her vehicle. On december 4TH the electrical system failed to work involving injected number 8. on december 11TH, injected number six on contact diesel engine truck failed while driving 55 mph. the contact…
TL*- the contact states that sometime in august of 2006, fuel injected number 8 failed in her vehicle. On december 4TH the electrical system failed to work involving injected number 8. on december 11TH, injected number six on contact diesel engine truck failed while driving 55 mph. the contact states that he has spent over $1,000 of dollars repairing his truck and would like to know, if the manufacturer has confirm that there IS a problem with the fuel injectors. The vehicle has been in for repair several of times, contact can provide any repair invoices if needed
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.
- 10250012Duramax Diesel Glow Plugs Difficult to Install Due to Carbon Buildup - New Glow Plug Bore Reamer Available
- 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
- 10246631Expanded Availability for Remanufacture and Return (R&R) Electronic Control Modules
- 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.
- 10242262This service bulletin provides graphics, information and guidelines for engine component wear to assist service personnel as a guideline to perform necessary engine repairs and prevent unnecessary engine replacement.
- 10242252This technical bulletin provides information and a solution to a condition of Brake Pedal Moves or Self Applies at Full Turns.
Every GMC Sierra 3500 model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.