VehicleVerdict

2004 Chevrolet W3500 problems

Verdict · NHTSA data

Limited data — recalls on file

NHTSA has just 9 complaints on file for the 2004 Chevrolet W3500 — too few to judge reliability from owner reports alone — but one recall campaign applies to this year, so any used example should have its VIN checked for completed recall work.

9

NHTSA complaints

1

Recalls

0

Investigations

0

Crash-involved

0

Fires reported

0

Injuries

0

Deaths

—

NCAP overall

How does 2004 compare to other W3500 years?

W3500 NHTSA complaints by model year, 2004 highlighted9 complaints1998: 1 complaints2000: 0 complaints2001: 2 complaints2003: 4 complaints2004: 9 complaints2005: 5 complaints2006: 4 complaints2007: 3 complaints2008: 0 complaints2009: 0 complaints
W3500 NHTSA complaints by model year, 2004 highlighted. Red bars are years to avoid.

See all W3500 years to avoid →

What are the most common 2004 Chevrolet W3500 problems?

ComponentComplaintsShare
Engine333%
Fuel System222%
Brakes111%
Electrical System111%
Body & Structure111%
Suspension111%

Does the 2004 Chevrolet W3500 have recalls?

1 NHTSA recall campaign on file. Recall repairs are free at franchised dealers.

05V168000Fuel SystemApril 20, 2005 · 253 units

Defect

ON CERTAIN TRUCKS EQUIPPED WITH RPO IK9, DUE TO INSUFFICIENT DURABILITY AND TESTING, THE FUEL SWITCHING MANIFOLD SOLENOIDS LACK WATER OR SALT INTRUSION RESISTANCE, WHICH CAN LEAD TO FAILURE OF ONE OR MORE SOLENOIDS. FUEL SWITCHING MANIFOLD SOLENOID FAILURE WILL CAUSE INCORRECT FUEL DELIVERY RESULTING IN FUEL OVERFLOW FROM THE FUEL FILLER NECK.

Consequence

OVERFLOW FUEL MAY RESULT IN HIGH AMOUNT OF DIESEL FUEL LEAKAGE. FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.

Remedy

DEALERS WILL REPLACE THE SOLENOID VALVE ASSEMBLY WITH AN IMPROVED ASSEMBLY INCLUDING ADDITIONAL DETECTION CIRCUIT AND ENHANCED WATER RESISTANCE FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 27, 2005. OWNERS MAY CONTACT ISUZU AT 1-800-255-6727.

Consumer complaints filed with NHTSA

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

“THE BOLTS ATTACHING THE EXHAUST MANIFOLD TO THE ENGINE ARE BROKEN OFF CAUSING EXHAUST LEAKS BOTH SIDE MOTOR. THE CAB OF THIS VEHICLE SITS OVER THE MOTOR SO YOU CAN SMELL RAW EXHAUST INSIDE THE VEHICLE.. THERE ARE SEVERAL COMPLAINTS POSTED ONLINE AND YOUTUBE ABOUT THIS PROBLEM. I HAVE A FRIEND THAT…”

Complaint filed with NHTSA · Engine · August 1, 2014

“WHILE DRIVING 65 MPH VEHICLE STALLED. VEHICLE WAS TOWED TO THE DEALER FOR INSPECTION, AND MECHANIC DETERMINED THAT FUEL PUMP, COMPUTER SENSOR, AND FUEL LINE NEEDED TO BE REPLACED ,AND REPLACED THEM. HOWEVER, THE PROBLEM RECURRED. *AK”

Complaint filed with NHTSA · Fuel System · July 5, 2004

“THE BOLTS ATTACHING THE EXHAUST MANIFOLD TO THE ENGINE ARE BROKEN OFF CAUSING EXHAUST LEAKS BOTH SIDE MOTOR. THE CAB OF THIS VEHICLE SITS OVER THE MOTOR SO YOU CAN SMELL RAW EXHAUST INSIDE THE VEHICLE.. THERE ARE SEVERAL COMPLAINTS POSTED ONLINE AND YOUTUBE ABOUT THIS PROBLEM. I HAVE A FRIEND THAT…”

Complaint filed with NHTSA · Body & Structure · August 1, 2014

“VEHICLE WAS TOWING A TRAILER. WHEN THE LEFT REAR SHOCK MOUNT BROKE OFF THE AXLE. THE BRAKE LINE IS BOLTED TO THE SHOCK MOUNT. WHEN THE MOUNT BROKE, IT TOOK OUT THE BRAKE LINE, WATCH RESULTED IN THE LOSE OF BRAKES. AFTER HAVING A WELDER LOOK AT THE BRACKET WE CAME TO THE CONCLUSION THAT THE WELDS…”

Complaint filed with NHTSA · Suspension · May 22, 2007

“WHILE DRIVING 65 MPH VEHICLE STALLED. VEHICLE WAS TOWED TO THE DEALER FOR INSPECTION, AND MECHANIC DETERMINED THAT FUEL PUMP, COMPUTER SENSOR, AND FUEL LINE NEEDED TO BE REPLACED ,AND REPLACED THEM. HOWEVER, THE PROBLEM RECURRED. *AK”

Complaint filed with NHTSA · Electrical System · July 5, 2004

2004 Chevrolet W3500 — common questions

Is the 2004 Chevrolet W3500 reliable?

The record is thin — 9 NHTSA complaints — so owner-report data can't strongly confirm reliability either way, though 1 recall should be verified as completed.

Does the 2004 Chevrolet W3500 have recalls?

Yes — NHTSA lists 1 recall campaign affecting the 2004 Chevrolet W3500. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

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.