2004 GMC Sierra 2500 problems

Verdict · NHTSA data

One of the years to avoid

With 175 complaints filed to NHTSA — about 3.1 times the median Sierra 2500 year — the 2004 model ranks #2 of 31 Sierra 2500 years for complaint volume. It lands on the years-to-avoid list. Reports tied to this model year include one death and 5 injuries, per the complaint records themselves.

Brakes leads the complaint categories with 56 reports (32% of the total).

175

NHTSA complaints

Recalls

Investigations

Crash-involved

Fires reported

Injuries

Deaths

—

NCAP overall

How does 2004 compare to other Sierra 2500 years?

Sierra 2500 NHTSA complaints by model year, 2004 highlighted. Red bars are years to avoid.

See all Sierra 2500 years to avoid →

What are the most common 2004 GMC Sierra 2500 problems?

Component	Complaints	Share	vs prior year
Brakes	56	32%	▼ down
Electrical System	51	29%	▲ up
Engine	18	10%	▲ up
Transmission	10	6%	▼ down
Fuel System	8	5%	▼ down
Steering	7	4%	▼ down
Body & Structure	5	3%	— flat
Tires & Wheels	4	2%	▲ up
Visibility & Wipers	3	2%	— flat
Airbags	2	1%	▲ up
Lighting	2	1%	▲ up
Other	2	1%	— flat
Seats	2	1%	▲ up
Speed Control	2	1%	▼ down
Suspension	1	1%	▼ down
Seat Belts	1	1%	— flat
Climate Control (A/C & Heat)	1	1%	— flat

Does the 2004 GMC Sierra 2500 have recalls?

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

06E050000BrakesJune 6, 2006 · 6,800 units

Defect

CERTAIN FEDERAL-MOGUL NATIONAL AND CARQUEST AFTERMARKET HUB ASSEMBLIES, P/N 515058, SOLD FOR USE ON 2001-2006 GENERAL MOTORS 1500 AND 2500 4WD TRUCKS. ON THE SUBJECT HUB ASSEMBLIES, THE ABS SENSOR CORD DEPARTS FROM THE HUB ASSEMBLY AT A 90 DEGREE ANGLE. AS A RESULT, THERE IS A FIT ISSUE WITH THE BRAKE ROTOR DUST SHIELD INTERFERING WITH THE ABS SENSOR CORD. IF THE HUB ASSEMBLY IS INSTALLED DESPITE THIS INTERFERENCE, THE GAP BETWEEN THE ABS SENSOR AND THE TONE WHEEL MAY BE ALTERED. THIS MAY WEAKEN THE OUTPUT OF THE ABS SENSOR. DIMINISHED OUTPUT COULD RESULT IN AN UNWANTED ABS ACTIVATION AT LOW SPEEDS AND STOPPING DISTANCE COULD BE AFFECTED.

Consequence

IF STOPPING DISTANCE IS LIMITED, A VEHICLE CRASH COULD OCCUR.

Remedy

FEDERAL-MOGUL WILL NOTIFY ITS OWNERS AND WILL EITHER CREDIT THE CUSTOMERS ACCOUNT OR REPLACE THE UNIT. THE RECALL IS EXPECTED TO BEGIN DURING JUNE 2006. OWNERS CAN CONTACT FEDERAL-MOGUL CUSTOMER SERVICE AT 1-800-563-8507 EXT 3530.

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.

04V562000OtherNovember 26, 2004 · 1,660 units

Defect

ON CERTAIN VANS EQUIPPED WITH SURE-LOK WHEELCHAIR SECUREMENT SYSTEMS, THE SPROCKET TEETH OF THE RETRACTOR ASSEMBLY IS OUT OF ALIGNMENT.

Consequence

IN THE EVENT OF A VEHICLE CRASH, THE WHEELCHAIR MAY NOT BE ADEQUATELY SECURED POSSIBLY RESULTING IN INJURIES TO A WHEELCHAIR OCCUPANT.

Remedy

DEALERS WILL INSPECT AND REPLACE THE WHEELCHAIR SECUREMENT RETRACTORS AS NECESSARY. SURE-LOK WILL HANDLE THE REPAIRS FOR THIS CAMPAIGN. OWNERS SHOULD CONTACT SURE-LOCK AT 1-908-231-1804 OR MOBILITYWORKS AT 1-800-769-8267.

Consumer complaints filed with NHTSA

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

“LOST BRAKES WHILE DRIVING 35 MPH WAS ABLE TO STOP AND NOTICED BRAKE FLUID DRIPPING FROM ABOVE GAS TANK JUST FORWARD OF REAR AXLE ON DRIVERS SIDE. NEW BRAKE LINE WAS INSTALLED AT GMC DEALER IN JULY 2010 AFTER IT BURST GOING 45 MPH SAME PROBLEM AS IN JULY 2010 THAT CAUSED AN ACCIDENT WITH PROPERTY…”
Complaint filed with NHTSA · Brakes · March 29, 2011 · crash

“TL*THE CONTACT OWNS A 2004 GMC SIERRA 2500 HD. WHILE DRIVING 55 MPH, THE VEHICLE BEGAN SMOKING NEAR THE GLOVE BOX. THE PLASTIC COATING ON THE WIRES BEGAN DRIPPING, MELTING, AND SPARKING. THE VEHICLE THEN BECAME ENGULFED IN FLAMES AND WAS DESTROYED. A POLICE AND FIRE REPORT WAS FILED. THE CONTACT…”
Complaint filed with NHTSA · Electrical System · January 30, 2008 · fire

“TL*THE CONTACT OWNS A 2004 GMC SIERRA 2500. THE CONTACT STATED THAT WHILE DRIVING AT 70 MPH, THE VEHICLE FAILED TO ACCELERATE AND THE FUEL RESTRICTION WARNING LIGHT ILLUMINATED. THE FAILURE OCCURRED MULTIPLE TIMES. THE VEHICLE WAS TOWED TO THE CONTACT'S HOME. THE VEHICLE WAS NOT DIAGNOSED OR…”
Complaint filed with NHTSA · Engine · January 20, 2015

“2004 GMC 2500 HD. PURCHASED MY TRUCK IN FALL OF 2003. MY SPEEDOMETER STOPPED WORKING PROPERLY. TRUCK ONLY HAS 45K MILES. DEALERSHIP ADVISED THE INSTRUMENT CLUSTER PANEL WAS BAD NEEDED TO BE REPLACED. NEW PART IS @ $210.00 PLUS LABOR. THE SEAL ON MY RIGHT FRONT AXLE IS ALSO STARTING TO LEAK. *TR”
Complaint filed with NHTSA · Transmission · September 13, 2007

“IN THE PAST THREE MONTHS THE FUEL LINES NEEDED REPLACEMENT AS THEY HAD RUSTED SO BADLY THAT A LEAK FORMED. YESTERDAY WHILE PULLING MY 10,000 POUND BOAT, MY BRAKES SUDDENLY FAILED BECAUSE OF A LEAK IN THE LINE BETWEEN THE ABS BOX AND THE RIGHT FRONT WHEEL. THE CATASTROPHIC FAILURE NEARLY CAUSED ME…”
Complaint filed with NHTSA · Fuel System · March 16, 2016

2004 GMC Sierra 2500 — common questions

Is the 2004 GMC Sierra 2500 reliable?

NHTSA data argues against it: 175 complaints put the 2004 model at #2 of 31 Sierra 2500 years. It is one of the Sierra 2500 years to avoid.

What are the most common 2004 Sierra 2500 problems?

According to NHTSA complaint data, the leading problem areas are brakes (56 complaints), electrical system (51 complaints), engine (18 complaints).

Does the 2004 GMC Sierra 2500 have recalls?

Yes — NHTSA lists 4 recall campaigns affecting the 2004 GMC Sierra 2500. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

Which GMC Sierra 2500 years should you avoid?

Based on complaint rates and open investigations, the Sierra 2500 years to avoid are 2003, 2004, 2001, 2002, 2005, 2024, 2020, 2015, 2007, 2011, 2008, 2013, 2012, 2014, 2009, 2010. The cleanest record among Sierra 2500 years belongs to 1994.

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

Compiled by Sharon Ben-Moshe, Founder.

How does 2004 compare to other Sierra 2500 years?

What are the most common 2004 GMC Sierra 2500 problems?

Does the 2004 GMC Sierra 2500 have recalls?

Consumer complaints filed with NHTSA

2004 GMC Sierra 2500 — common questions

Is the 2004 GMC Sierra 2500 reliable?

What are the most common 2004 Sierra 2500 problems?

Does the 2004 GMC Sierra 2500 have recalls?

Which GMC Sierra 2500 years should you avoid?

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