VehicleVerdict

2004 Chevrolet Silverado 2500 problems

Verdict · NHTSA data

One of the years to avoid

With 431 complaints filed to NHTSA — about 4.3 times the median Silverado 2500 year — the 2004 model ranks #2 of 33 Silverado 2500 years for complaint volume. It lands on the years-to-avoid list. Reports tied to this model year include 4 deaths and 12 injuries, per the complaint records themselves.

The trouble concentrates in one system: brakes issues account for 40% of all reports (174 of 431), far ahead of electrical system at 105.

431

NHTSA complaints

2

Recalls

0

Investigations

23

Crash-involved

11

Fires reported

12

Injuries

4

Deaths

—

NCAP overall

How does 2004 compare to other Silverado 2500 years?

Silverado 2500 NHTSA complaints by model year, 2004 highlighted561 complaints1994: 7 complaints1995: 6 complaints1996: 2 complaints1997: 74 complaints1998: 82 complaints1999: 95 complaints2000: 156 complaints2001: 379 complaints2002: 408 complaints2003: 561 complaints2004: 431 complaints2005: 337 complaints2006: 218 complaints2007: 253 complaints2008: 226 complaints2009: 79 complaints2010: 27 complaints2011: 128 complaints2012: 69 complaints2013: 71 complaints2014: 52 complaints2015: 245 complaints2016: 156 complaints2017: 69 complaints2018: 69 complaints2019: 101 complaints2020: 134 complaints2021: 103 complaints2022: 123 complaints2023: 64 complaints2024: 202 complaints2025: 30 complaints2026: 4 complaints
Silverado 2500 NHTSA complaints by model year, 2004 highlighted. Red bars are years to avoid.

See all Silverado 2500 years to avoid →

What are the most common 2004 Chevrolet Silverado 2500 problems?

ComponentComplaintsShare
Brakes17440%
Electrical System10524%
Engine379%
Fuel System266%
Steering184%
Transmission164%
Tires & Wheels153%
Suspension123%
Other61%
Speed Control61%
Visibility & Wipers41%
Body & Structure41%
Airbags41%
Lighting20%
Latches & Locks10%
Climate Control (A/C & Heat)10%

Does the 2004 Chevrolet Silverado 2500 have recalls?

2 NHTSA recall campaigns on file. Recall repairs are free at franchised dealers.

06E043000Fuel SystemMay 19, 2006 · 88,303 units

Defect

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, CLICK ON "DOCUMENT SEARCH" AND THEN "BUS APPLICATIONS"). THE CONNECTOR ON THE FUEL FILTER WAS NOT MANUFACTURED TO HONEYWELL'S SPECIFICATION. AS A RESULT, THE O-RING MAY NOT SEAT CORRECTLY ON THE FUEL LINE.

Consequence

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).

06E010000SteeringFebruary 1, 2006 · 1,360 units

Defect

CERTAIN FABTECH AFTERMARKET REPLACEMENT PITMAN ARMS, P/NOS. FTS71000 AND FTS71001, INSTALLED FOR USE ON CERTAIN 2001-2006 GM C/K 2500 PICK UP TRUCKS AND SPORT UTILITY VEHICLES. THE PIN LOCATED INSIDE THE PITMAN ARM CAN SHEAR OFF DUE TO A REVERSE BENDING FATIGUE CONDITION, RESULTING IN A TOTAL LOSS OF STEERING CONTROL.

Consequence

LOSS OF STEERING CONTROL COULD LEAD TO A VEHICLE CRASH WITH POTENTIAL INJURY OR DEATH.

Remedy

FABTECH WILL NOTIFY OWNERS AND REPLACE THE PITMAN AND IDLER ARMS FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING FEBRUARY 2006. OWNERS MAY CONTACT FABTECH AT 909-597-7800.

Consumer complaints filed with NHTSA

Representative excerpts, cleaned of personal information. These are consumer statements, not verified defects.

“I WAS DRIVING AT NORMAL SPEED AND WAS TRAVELING DOWN A BACK ROAD WITH A CAR DOLLY ON BACK WHEN I CAME UP OVER THE HILL THERE WERE CARS STOPPED AND THE OTHER LANE WAS COMING TOWARDS TRAFFIC I TRIED AT THE TOP OF A VERY STEEP HILL TO APPLY MY BRAKES AND THEY FAILED CAUSING ME TO HIT 6 CARS AND ONE…”

Complaint filed with NHTSA · Brakes · August 17, 2013 · crash

“TL*THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500 HD. THE CONTACT STATED THAT THE HEATER ELECTRICAL RESISTOR, AND CONNECTORS MELTED CAUSING THE HEATER BLOWER TO FAIL. THE VEHICLE WAS TAKEN TO THE DEALER WHO REPLACED THE CONNECTORS, AND RESISTORS. THE MANUFACTURER WAS CONTACTED, BUT THEY WILL NOT…”

Complaint filed with NHTSA · Electrical System · July 1, 2010 · fire

“TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500. THE CONTACT STATES HE WAS DRIVING AT ABOUT 55MPH ON THE HIGHWAY WHEN HE NOTICED THERE WAS SMOKE COMING FROM UNDER THE HOOD AND THREW THE HEATER VENTS INTO HIS VEHICLE. THE CONTACT STATES HE PULLED HIS VEHICLE OVER INTO A PARKING LOT AND BY THE…”

Complaint filed with NHTSA · Engine · March 11, 2010 · fire

“TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500 HD. WHILE DRIVING HE SAW SMOKE COMING FROM THE TAIL PIPE, AND THEN HE SMELLED A BURNING ODOR. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION. THE TECHNICIAN CONCLUDED THAT THE THERMOSTATS ARE NOT ALLOWING THE VEHICLE TO ACHIEVE OPERATING…”

Complaint filed with NHTSA · Fuel System · October 15, 2009 · fire

“(1) I WAS IN A TIGHT TURN. I HAD JUST HAULED 2 TONS OF FEED FROM A FEED MILL 30 MILES AWAY. (2) THE POWER STEERING AND BRAKES BOTH STOPPED WORKING SUDDENLY AND WITH NO WARNING. I HAD NO CONTROL OVER MY VEHICLE AND HAD TO RUN INTO A FENCE POST TO STOP IT. HAD IT HAPPENED A FEW MINUTES EARLIER WHILE…”

Complaint filed with NHTSA · Steering · August 15, 2006 · crash

2004 Chevrolet Silverado 2500 — common questions

Is the 2004 Chevrolet Silverado 2500 reliable?

NHTSA data argues against it: 431 complaints put the 2004 model at #2 of 33 Silverado 2500 years. It is one of the Silverado 2500 years to avoid.

What are the most common 2004 Silverado 2500 problems?

According to NHTSA complaint data, the leading problem areas are brakes (174 complaints), electrical system (105 complaints), engine (37 complaints).

Does the 2004 Chevrolet Silverado 2500 have recalls?

Yes — NHTSA lists 2 recall campaigns affecting the 2004 Chevrolet Silverado 2500. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

Which Chevrolet Silverado 2500 years should you avoid?

Based on complaint rates and open investigations, the Silverado 2500 years to avoid are 2003, 2004, 2002, 2001, 2005, 2007, 2015, 2008, 2006, 2024, 2016, 2000, 2011, 2009, 2013, 2012, 2014, 2010. The cleanest record among Silverado 2500 years belongs to 1996.

Related

Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.

Compiled by Sharon Ben-Moshe, Founder.