2004 GMC W4500 problems

Verdict · NHTSA data

Limited data — recalls on file

NHTSA has just 2 complaints on file for the 2004 GMC W4500 — 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.

NHTSA complaints

Recalls

Investigations

Crash-involved

Fires reported

Injuries

Deaths

—

NCAP overall

How does 2004 compare to other W4500 years?

W4500 NHTSA complaints by model year, 2004 highlighted. Red bars are years to avoid.

See all W4500 years to avoid →

What are the most common 2004 GMC W4500 problems?

Component	Complaints	Share	vs prior year
Brakes	1	50%	— flat
Fuel System	1	50%	new

Does the 2004 GMC W4500 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.

“TL*THE CONTACT OWNS A 2004 GMC W4500. THE CONTACT REFERENCED NHTSA RECALL CAMPAIGN ID NUMBER: 05V168000, FUEL SYSTEM, DIESEL:STORAGE:TANK ASSEMBLY. WHILE DRIVING 30 MPH THE VEHICLE STARTED TO HESITATE. HE TOOK THE VEHICLE TO A LOCAL MECHANIC AND THEY CLEANED THE FUEL TANK. THE FOLLOWING DAY HE…”
Complaint filed with NHTSA · Fuel System · May 5, 2010

“TL*THE CONTACT OWNS A 2004 GMC W4500. THE CONTACT REFERENCED NHTSA RECALL CAMPAIGN ID NUMBER: 05V168000, FUEL SYSTEM, DIESEL:STORAGE:TANK ASSEMBLY. WHILE DRIVING 30 MPH THE VEHICLE STARTED TO HESITATE. HE TOOK THE VEHICLE TO A LOCAL MECHANIC AND THEY CLEANED THE FUEL TANK. THE FOLLOWING DAY HE…”
Complaint filed with NHTSA · Brakes · May 5, 2010

2004 GMC W4500 — common questions

Is the 2004 GMC W4500 reliable?

The record is thin — 2 NHTSA complaints — so owner-report data can't strongly confirm reliability either way, though 1 recall should be verified as completed.

Does the 2004 GMC W4500 have recalls?

Yes — NHTSA lists 1 recall campaign affecting the 2004 GMC W4500. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

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 W4500 years?

What are the most common 2004 GMC W4500 problems?

Does the 2004 GMC W4500 have recalls?

Consumer complaints filed with NHTSA

2004 GMC W4500 — common questions

Is the 2004 GMC W4500 reliable?

Does the 2004 GMC W4500 have recalls?

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