VehicleVerdict

2004 GMC Sierra 3500 problems

Verdict · NHTSA data

Limited data — recalls on file

NHTSA has just 29 complaints on file for the 2004 GMC Sierra 3500 — 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.

29

NHTSA complaints

1

Recalls

0

Investigations

0

Crash-involved

2

Fires reported

0

Injuries

0

Deaths

—

NCAP overall

How does 2004 compare to other Sierra 3500 years?

Sierra 3500 NHTSA complaints by model year, 2004 highlighted72 complaints1996: 2 complaints1997: 15 complaints1998: 12 complaints1999: 25 complaints2000: 30 complaints2001: 44 complaints2002: 29 complaints2003: 9 complaints2004: 29 complaints2005: 29 complaints2006: 14 complaints2007: 19 complaints2008: 27 complaints2009: 8 complaints2010: 2 complaints2011: 24 complaints2012: 15 complaints2013: 15 complaints2014: 10 complaints2015: 40 complaints2016: 27 complaints2017: 18 complaints2018: 20 complaints2019: 19 complaints2020: 72 complaints2021: 28 complaints2022: 39 complaints2023: 41 complaints2024: 62 complaints2025: 25 complaints2026: 3 complaints
Sierra 3500 NHTSA complaints by model year, 2004 highlighted. Red bars are years to avoid.

See all Sierra 3500 years to avoid →

What are the most common 2004 GMC Sierra 3500 problems?

ComponentComplaintsShare
Brakes1448%
Electrical System517%
Fuel System414%
Steering27%
Transmission27%
Tires & Wheels13%
Body & Structure13%

Does the 2004 GMC Sierra 3500 have recalls?

1 NHTSA recall campaign 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).

Consumer complaints filed with NHTSA

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

“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…”

Complaint filed with NHTSA · Brakes · August 2, 2013

“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”

Complaint filed with NHTSA · Electrical System · November 1, 2008

“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…”

Complaint filed with NHTSA · Fuel System · July 7, 2005 · fire

“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…”

Complaint filed with NHTSA · Steering · April 23, 2008

“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…”

Complaint filed with NHTSA · Transmission · October 11, 2007

2004 GMC Sierra 3500 — common questions

Is the 2004 GMC Sierra 3500 reliable?

The record is thin — 29 NHTSA complaints — so owner-report data can't strongly confirm reliability either way, though 1 recall should be verified as completed.

What are the most common 2004 Sierra 3500 problems?

According to NHTSA complaint data, the leading problem areas are brakes (14 complaints), electrical system (5 complaints), fuel system (4 complaints).

Does the 2004 GMC Sierra 3500 have recalls?

Yes — NHTSA lists 1 recall campaign affecting the 2004 GMC Sierra 3500. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

Which GMC Sierra 3500 years should you avoid?

Based on complaint rates and open investigations, the Sierra 3500 years to avoid are 2020, 2024, 2001, 2023, 2015, 2022, 2008, 2011, 2007, 2013, 2012, 2014, 2009, 2010. The cleanest record among Sierra 3500 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.