Which parts fail
Components named in complaints (doors, hood, frame, rust, paint and trim).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Chevrolet Colorado owners, lightly cleaned up (personal details are redacted by NHTSA).
I was checking on the common rear cab rust and noticed the frame looked rusted through just in front of the rear wheel suspension mount. I took it to my local mechanic (Bob's Repair of Mayer) and they said it was not safe to drive. It is a complete blindside to me and now I have to find a spare (safe) car to help drive around my newborn and toddler. I am going to attempt to repair the frame as I do not have any other options for vehicles. There were obviously no warnings are notices that about this issue, but it seems to be uncannily common for this generation of Chevrolet vehicles. The truck only has 160,000 miles on it and surface rust on the cab. The vehicle is not drivable and not safe as the frame could give away at any moment.
Mechanic had the truck on the lift raised up to check the brakes for squeaking and while under the truck the mechanic inspected the frame because he noticed a lot of rust and called me to come look at it and pointed out that the frame has rotted to the point that he should not be driven and could break in half and cause major problems for the safety of the occupants and other drivers on the road. I looked up online if other Colorado owners had the same issue and others have the same problem. I'm am forced to junk this vehicle even though the rest of the truck is in very good condition
I currently own a 2004 Chevrolet Colorado miles are 107,650. My truck is in very good to excellent shape, I take pride in my vehicles. The issue I have is my frame is rotten and cracked at the leaf spring hangers, much to my surprise when I jacked my truck up to change over tires and the rear axle stayed on the ground. Im very grateful we caught this before the right side broke away like the left side did. I do live in maine and they use products on the roads for ice, but my fuel and brake lines are in very good serviceable condition, as is most everything under the truck including the bed. I have been looking for guidance and stumbled onto some "forums" that state first gen Colorado this is common. …
During a visit to the mechanic for a routine brake job on May 17, 2017, the mechanic refused to work on my 2004 Chevrolet Colorado due to safety issues involving the rust on the frame. I was turned away and given a receipt with the following in the "notes" section: "-vehicle is completely unsafe to drive - frame is rusted throughout truck, and where the driver side leaf spring is welded to the frame, it has fractured off. Any small bump / accident / shutter could break what is left off, and the rear axle will come detached from the vehicle at the point - customer has been informed." this truck has spent only 12 years on the east coast of the us and the mechanic blamed the road salt for the rust. The body and interior of this truck are very clean and I have always taken great care of it. …
Chevy Colorado trucks risk of fire! This truck is on its 3rd A/C & heat fan speed control resister and corresponding connecting plug. The first two were covered under the factory warranty, this last one was not. Each resister and plug in connector has been on the verge of catching on fire. At times you can smell smoke in the truck. If the fan speed control is on 1,2,or 3. Off & 4/high work OK. Each plug has melted and is a charred black and the contacts are no longer supported by the plug. The intense heat has charred the resistors corresponding connection socket. I have photos of the resister and plug for your inspection. Upon request. And the old units for you. If you do a web search for Chevy fan or blower speed control stops working you will find this is a common problem. …
Tl* the contact owns a 2004 Chevrolet Colorado. While the gear shifter was placed in reverse, the shift linkage failed and the shift cable snapped. The vehicle was taken to west Chevrolet at [phone] (3450 alcoa hwy, alcoa, tn 37701) where the shift cable was replaced. Upon further inspection, the dealer noticed that the frame was rusted and corroded. The contact was informed that the vehicle was unsafe to drive and that the frame needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure and did not assist. The failure mileage was 115,440.
Tl* the contact owns a 2004 Chevrolet Colorado. While driving various speeds, a crunch noise was coming from the rear of the vehicle. Each time the vehicle drove over a bump in the road, the noise grew louder. The vehicle was not taken to the dealer. The vehicle was taken to an independent mechanic where it was diagnosed that the frame had corroded through and the suspension was detached. The vehicle was not repaired. The manufacturer informed the contact that the vehicle was out of warranty and did not offer further assistance. The approximate failure mileage was 124,300.
Vehicle has 96,800 miles, and the frame has completely rusted through causing the rear suspension to detach from the frame, as well as the bed to detach from the frame. Vehicle is no longer able to be put on lift to have tires rotated as the frame disintegrates upon contact. This is a very well known problem, and I am curious why the federal government has not forced GM to recall these vehicles like Toyota was forced to do with their identical situation. Do your jobs, and hold these corporations accountable for cheap workmanship.
Tl* the contact owns a 2004 Chevrolet Colorado. While driving various speeds, the frame of the vehicle fractured. The contact heard a loud popping noise on more than one occasion, which indicated that the frame had come apart. Mid-state Chevrolet Buick of sutton west virginia (1947 sutton lane, 26601) was made aware of the failure and stated that there were no recalls on the vehicle. The vehicle was not repaired. The manufacturer was made aware of the issue and referred the contact to NHTSA. The failure mileage was 167,000.
I went to install brakes when the mechanic noticed the jounce bumber missing, but when he looked closer he noticed it was rotted. The jounce buper bracket is part of the frame and it completely rotted out. I called GM and they inspected it and they said there is nothing they could do. I said Toyota replaced all the chasis rotting out in the state of massachusetts, this would be the same the salt brine is rooting out frames and this vehicle is no longer safe. They will not even buy it back. I need your help.
Body complaints in other Colorado years
Frequently asked questions
How common are body problems on the 2004 Chevrolet Colorado?
NHTSA has 61 complaints about the body & structure of the 2004 Chevrolet Colorado, 17% of the model year's 361 complaints. The component named most often is body (40 mentions).
Is there a recall for 2004 Chevrolet Colorado body problems?
No. NHTSA lists no body & structure recall for the 2004 Chevrolet Colorado, though it has 3 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 Chevrolet Colorado body problems start?
Half of the complaints with a recorded mileage happened before about 115,000 miles, and 11% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 0 fires and 0 injuries to body & structure problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.