Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Chevrolet Silverado 1500 owners, lightly cleaned up (personal details are redacted by NHTSA).
Front Suspension repaired fixed but did not fixed the vibration in front tires. Front Driver Side Hub and Bearing Assembly Failed since I had truck(used). Had front end redone but wheel still vibrated and took it too dealership July 3, 2021 and stated the Hub and Bearing grinding and growling and activates abs lights. Fuel line needs replace due to rust problems and dealership stated that the pump and retaining cam are very rusted and has a spot on the pump that is wet but not soaking wet(fail dealership looking for lawsuit for fire hazard). Fuel lines are rusted so whole truck needs repair. I spent $5400 on used truck and putting more money into it with repairs due to rust, parts and labor which is stupid as some parts do not take long if dealership have tools. I don't know incident as there no accident or anything.
On July 22, 2015 I was driving my 2004 Chevy Silverado 1500 and when I went to stop at an intersection the brakes failed and I had go through a stop sign. I had to hit the emergency brake to get the truck stopped. I was lucky it happened in a housing sub division and not on an interstate because someone could have been killed. I was close to my mechanics garage and was able to get it into the garage where I was informed that all of my brake lines were completely corroded and rusted through he also informed me that a brake caliper needed replaced due to all of the brake line corrosion. The mechanic also informed me that all the fuel lines were corroded and also needed replaced. The mechanic told me he has replaced brake lines on several Silverado's all due to corrosion. This truck only has 65,665 miles on it and was seldom driven in snow. …
Tl* the contact owns a 2005 Chevrolet trailblazer. While driving approximately 60 MPH, the contact noticed that the driver side headlight failed. The contact replaced the bulb three different times but the failure recurred. The vehicle was taken to an independent mechanic for diagnostics where the mechanic advised that the headlight wires were melted and the headlight assembly would have to be replaced. The vehicle was not repaired. The VIN was not available. The approximate failure mileage was 98,000. Updated 02/27/15 the dealer stated the consumers instrument cluster needs to be repaired.
Tl* the contact owns a 2004 Chevrolet Silverado 1500. The contact stated that the brake lines were rotted through and were replaced. The contacted stated that the fuel lines were also rotted and spilled fuel all over the place. There was no warning indicator illuminated. Also, while the vehicle was at a stop, the brake pedal traveled all the way to the floorboard. The contact used the emergency brake to pull off the road. The dealer and manufacturer were not made aware of the failures. The failure mileage was approximately 60,000.
Tl* the contact owns a 2004 Chevrolet Silverado 1500. During an oil change, it was noticed that the fuel line was rusted out. The vehicle was taken to rocket Chevrolet [phone], located at 233 mansfield ave, shelby, oh 44875) where it was confirmed that the fuel line was rusted out and needed to be replaced. The manufacturer was called, but no one answered the phone. The vehicle was not repaired. The failure mileage was approximately 54,000.
The gas gauge became very inaccurate and then stopped working altogether. Then the alternator gauge stopped being accurate. Works sometime and others it indicates max amps. Checked with a meter and the charge, with motor running is 14.2. My brother had a 2003 when the same happen, cost him 400.00 to have instrument package replaced. This should have been a recall to replace defective instrument package.
Vehicle speeds up, surges, then starts to buck and you get transmission lash. It happens at road and highway speeds of 45 or 55 MPH, and can/does happen in od or in 3rd gear. (automatic transmission). I have had a third party "scan" the system, and I get "no" codes. Check engine light does "not" come on. I am able to replicate the issue at will. The vehicle is a 2004 k1500 with 46,500 miles. Its primary use since I purchased this vehicle new is to tow a 19 foot mastercraft from April to November. Maintenance is performed by the manufactures' recommended guidelines. Orginal tires, air and oil filters have been changed as needed. No aftermarket devices installed. I have had a couple of verbal encounters with Chevy dealer service department. They seem to be clueless. But are willing to troubleshoot at my expense, plus costs of all parts and service hours. …
While traveling to work I attempted to stop and the brake pedal went all the way to the floor. I was able to stop by using only the emergency brake but only after approx. 100 feet. I was able to drive the truck home by using four wheel low and allowing the engine and transmission to keep me at a safe speed. I then contacted my mechanic who lives right down the road and he came up and looked at the truck. He told me the brake line had ruptured and additionally all the brake lines should be replaced along with the fuel line that appears to be badly corroded. I then contacted the dealership where I purchased the truck and was told that they have had no issues with the brake lines on these trucks and there was nothing they could do to help me. …
I was replacing two bad o2 sensors and felt something wet on my fingers, that smelled like gas. When I started the truck to move it I notice a drip trail off gas. I took the truck to my mechanic and was advised that the gas lines were rusted/rotted through and needed to be replaced. I have never had to replace gas lines or brake lines on another vehicle. This is very unusual. I think these gas lines and the brake lines I reported earlier were made of inferior material. I do feel extremely fortunate that I did not crash or catch on fire.
While leaving my driveway I went to stop , pedal went to floor,car almost had accident with oncoming snow plow truck. Even though vehicle has low mileage dealer said warranty was up. Front brake lines were rusted through. Had them replaced. Just recently I checked under vehicle & it appears the same is happening to the rear brake lines & fuel lines. Rossi chev. My dealer told me this is a common problem. Something is not right with this very dangerous problem.
Fuel System complaints in other Silverado 1500 years
Frequently asked questions
How common are fuel system problems on the 2004 Chevrolet Silverado 1500?
NHTSA has 21 complaints about the fuel & propulsion system of the 2004 Chevrolet Silverado 1500, 3% of the model year's 797 complaints. The component named most often is delivery › fuel pump (2 mentions).
Is there a recall for 2004 Chevrolet Silverado 1500 fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2004 Chevrolet Silverado 1500. 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 Silverado 1500 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 78,000 miles, and 6% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 0 injuries to fuel & propulsion 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.