Which parts fail
Components named in complaints (battery, alternator, wiring, ignition, instrument cluster, infotainment).
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).
Body Control Module, BCM. Controls everything. Air bag can deploy, breaks can lock up. Mine, the hazards were staying on. Chevy Dealer says they are on National Back Order and GM is canceling those orders after so long placed. "We can get you one from a junk yard for $350 but GM won't let us properly program them with correct codes, and so many times they won't take, and I can't return the part". My response to GM already and to Congressman Westerman, BBB, and the WH. A part such as the on board computer, SAFETY first, should never come from a junk yard and if GM doesn't want to supply the part AS we all know they need them for newer cars right now..... You, the NHTSB and all of us are in danger. There is an expiration date on our cars, but we're not being told. A computer that controls EVERYTHING in a vehicle is more important than a safety belt. Me not wearing it kills me. …
One day, after I turned my truck off, I noticed that my taillights and overhead cargo light remained on. Key was out, truck was off, but the lights stayed on. So for the time being, I disconnected the battery. I brought it to a mechanic, who ran the codes that came back that the rear driver turn signal was high, the rear passenger turn signal was high, and the overhead cargo light was high. He checked the entire truck for a short, replaced the taillights, replaced the fuse box, replaced the body control module, and numerous other attempts at a repair, with no success. I was without a vehicle for many months, since I can't afford the absurd prices of the current vehicle market and was hopeful it could be fixed. Reading through some other complaints/online threads, this seems like a fairly common problem with these vehicles. …
Ignition safety module known as pass lock security. This causes my vehicle not to start and give a code and a light on the dash for the Pass Lock security. The vehicle was fine then I went into a store came out and put the key in the ignition, the lights on the dash came on but it would not crank. This is very hazardous cause It could happen while you're driving anytime, which could cause the vehicle to go into security mode and turn vehicle off making it very dangerous for passengers in vehicle. This is a problem with other Chevy Colorado's when I research this problem.
I too have experienced problems with the HVAC system of this truck. I have had to replace no less than 4 resistors and connectors due to melting and burned connections. I have not had to replace a single fuse. My HVAC is once again inoperable and I have opened and inspected each connection point to locate the problem. I have found multiple connectors to be burned or melted. This problem has been flagged by the nhsta in the Hummer h3 vehicles which use the same HVAC system. The Chevrolet/GMC/Isuzu Colorado/canyon (gmt355) should be included in this recall. There is no reason these connections should get hot enough to bubble and burn plastic before burning out a fuse. I can provide images upon request. I can also provide an example of a failed connector in the HVAC speed control switch for physical inspection. …
The brake light switch has failed multiple times. It was covered twice under a recall. Switches only last 1.5-2 years. There is no warning or dash light when they go out. I have almost been rear ended twice. Happened again April 13, 2015. I drove it straight to the dealer when I found out in traffic. I knew it was the brake switch again and the dealer confirmed. The dealer called GM to see if they would cover the replacement. They refused. The dealer gave me a discount as they know it is an issue and charged me $87 to change. This is the second time I have had to pay. He gave me this number to call but that was no use as they refused last time. [phone]. Most concerning to me is the lack of concern by GM to fix a know safety issue in the brake and light system. Someone probably has or will be seriously injured or killed. …
The dashboard lights will stop working if your driving at night and turn the car off and then turn it back on. They will not work until the car sits for a long period of time. This started soon after buying the car brand new, but the dealership couldn't find anything wrong. Second complaint, the heater/air conditioner fan had an electrical fire at where the harness plugs into the fan motor. The fan will only work on high. When I looked online at other complaints about the same problem, I unplugged the fan and noticed the plug was burnt. I have photos that I can send. It appeared the electrical fire continued down the plastic plug to where the wires are exposed. This could have been a major incident if I didn't notice it. There are a lot of complaints about this with Colorado trucks online. …
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. …
Idle control via electronic throttle body raises RPM very high when the accelerator pedal is not depressed, causing uncontrolled acceleration of vehicle during coasting or when brake pedal is applied. Turning the vehicle off with the key is the only action that has resulted in a cessation of extremely high idle. After restarting the vehicle, the symptom is gone and the vehicle operates normally. This behavior is erratic and inconsistent, the problem has been difficult to duplicate during diagnosis. All testing and inspection of the electronic throttle body, wiring harness, connectors, and functions within the engine computer has shown no defect or indication that a wiring fault, dirty throttle body, or other "wear and tear" item is the cause of this intermittent revving at idle. The most recent event occurred on August 9th 2017. …
Vehicles BCM-body control module is defective or the system in its self is defective. Vehicles will not start or May shut off at random from time to time. Scan tools will not be able to recognize the problem as the BCM. So repairs made May make it seem like it fixed the problem but a couple hours/days/weeks later the problem will disguise it self as something else or even come back as the same problem. I myself was told it was the starter and hey it worked, until 3 hours later. Then told the ignition passlock was defective, got it fixed until 1 hour later. Now I have narrowed it down to what controls the whole system, the BCM. Many people have complaints about this same issue all over the web forums, I dont know if any has been reported to NHTSA. So I figured I would start. I have this system effects 2004-2012 models of Chevy Colorado, GMC canyon and Hummer h3.
Everyday now when I try to start the truck it turns over but will not start, wait 15 minutes then it will start. Today when I tried it the first time it turned over but would not start so when I turned it off at the key it stopped then tried to start again on its own for about 8 to 10 secs. The starter turned the engine over without touching the ignition switch it then stopped for about 3 or 4 secs then tried to start on its own again without touching the key, it did this start sequence 3 times in a row. The GM passlock system is terribly defective as reported by all the reports online and I believe my problems are a result of this system.
Electrical complaints in other Colorado years
Frequently asked questions
How common are electrical problems on the 2004 Chevrolet Colorado?
NHTSA has 88 complaints about the electrical system of the 2004 Chevrolet Colorado, 24% of the model year's 361 complaints. The component named most often is 12v/24v/48v battery (3 mentions).
Is there a recall for 2004 Chevrolet Colorado electrical problems?
No. NHTSA lists no electrical system 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 electrical problems start?
Half of the complaints with a recorded mileage happened before about 75,000 miles, and 18% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 7 fires and 2 injuries to electrical system 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.