VehicleVerdict

2004 Chevrolet W5500 problems

Verdict · NHTSA data

Limited data — recalls on file

NHTSA has just 0 complaints on file for the 2004 Chevrolet W5500 — 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.

0

NHTSA complaints

1

Recalls

0

Investigations

0

Crash-involved

0

Fires reported

0

Injuries

0

Deaths

—

NCAP overall

How does 2004 compare to other W5500 years?

W5500 NHTSA complaints by model year, 2004 highlighted1 complaints2004: 0 complaints2006: 0 complaints2007: 0 complaints2008: 0 complaints2009: 0 complaints
W5500 NHTSA complaints by model year, 2004 highlighted. Red bars are years to avoid.

See all W5500 years to avoid →

Does the 2004 Chevrolet W5500 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.

2004 Chevrolet W5500 — common questions

Is the 2004 Chevrolet W5500 reliable?

The record is thin — 0 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 W5500 have recalls?

Yes — NHTSA lists 1 recall campaign affecting the 2004 Chevrolet W5500. 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.