Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Chevrolet Silverado 2500 owners, lightly cleaned up (personal details are redacted by NHTSA).
I experienced a sudden loss of engine power while travelling at highway speed. I am the original owner of a 2004 Chevrolet Silverado 2500 four wheel drive with the duramax diesel and allison transmission. On Sunday, October 4, 2015, shortly after a fuel stop, I was traveling on interstate 24 near paducah, ky. At approximately 65 MPH in the left lane with the cruise control set, I experienced a sudden loss of power accompanied by a loud engine rattling, and the check engine light came on. With some difficulty in heavy traffic, I was able to maneuver to the right shoulder of the road. I was able to drive the vehicle at about 25 MPH on the shoulder. Since I was just a few miles from the paducah exit, I limped there and into a hampton inn parking lot. Aaa responded and towed the truck to royal oaks Chevrolet in paducah. Since it was a Sunday, the service department was closed. …
Tl* the contact owns a 2004 Chevrolet Silverado 2500 hd. The contact stated that while towing a trailer at approximately 55 MPH, a clicking noise was heard from the engine and the engine exploded. The contact also observed smoke rising from the engine during the failure. The vehicle was towed to an independent repair shop where the contact was informed that the engine exploded and all of its components were melted. The vehicle was then towed to an authorized dealer where the failure was confirmed and the contact was advised that the engine was destroyed. The vehicle was repaired. The manufacturer was made aware of the failure, but offered no assistance. The failure mileage was 55,000.
Tl* the contact owns a 2004 Chevrolet Silverado 2500. The contact states he was driving at about 55mph on the highway when he noticed there was smoke coming from under the hood and threw the heater vents into his vehicle. The contact states he pulled his vehicle over into a parking lot and by the time he stepped out of his vehicle there was flames coming from under the hood. The contact also states the hood would not open. The fire department was contacted and when they arrived there it took them a hour to put the fire out. The fire report is available.the contact states he was not injured. The vehicle was destroyed. The failure mileage was 43,000. Ar
I have changed all 4 new tires in 4 different times every yrs not sure if that a wheel problem. And also fix my fuel injection system that was give me a problem in the past. Now I replace all new rotor brake discs and pad in 30 minutes out from a mechanical shop it's show a engine light now saying range shift inhibited on my dashboard. And when I'm shifting to drive it just reverse instead of drive. Now is back in the shop for now problem to come. From garden city kansas
Passenger side exhaust manifold bolts rust and break off on all GM full size trucks. I have 2004 Silverado 2500 hd with 61K miles, problem started at 56K miles as a mild tick that went away when engine warmed up and progressed to constant leak when engine was under load , two rear exhaust manifold bolts broke off causing exhaust leak. Seems all truck engines have this problem from 1999 -2007. This sounds like a manufacturing defect that should be addressed by GM .
Tl* the contact owns a 2004 Chevrolet Silverado 2500. While the vehicle was stationary smoke appeared from the engine it was diagnosed that the fuel injector needed to be replaced on the driver's side the vehicle was repaired, but the failure recurred. The manufacturer was made aware of the failure. The failure mileage was 157,000. Updated 02/24/17 updated 7/11/18
Exhaust manifold bolts breaking off. Almost everyone I know is having this problem with the v8 GM engines. Leads to exhaust leaks, sensor failures and bad catalytic converters- thus failing emissions testing. Hard and expensive to fix.
Bought the truck in October of 2009, took to dealership on 12/17/2009 with complaints mileage of 96,764 of low engine power, hard to start truck,,,,glow plugs were bad corroded park neutral switch, corrosion on brake lines..paid $ 3,600 in repairs then around late September 9-28-2010truck died a fourway intersection...was almost hit by a car...towed to nearest service fleet source...found out injectors were bad...work was started for repairs...then I found out the glow plugs...which I paid for already...and the injectors were service bulletins...called fleet told them to stop repairs...called the dealership...that had the truck in December...ask why they charged me for the glow plugs and why the did not fix the injectors...when it was in there.....dealership hung up on me...called [phone]..spoke with GM told them about my Chevy problems...they claim that my injectors would not be …
Recently I developed an exhaust leak near the front of the exhaust system near the engine. Upon inspection I found the back manifold bolt had been broken off on the drivers side (I May also have a broken bolt on the passenger side as well). I took the vehicle to my locally respected mechanic with the intention of having the broken bolt removed and a new one installed. I was notified that this was a common problem with these GM vehicles (2004 Silverado 2500hd). I was further informed that there was no way the repair would be simple due to the fact there was no practical manner in which to extract/drill out the broken bolt for replacement. I was told the head would need to be removed in order to effect the required repair which would cost somewhere between $700-$1000. This repair is not cost effective to me for what is probably a $3.00 bolt. …
Engine on passenger side all rusting exhaust manifold bolts rotted and broke off causing an exhaust leak that effects sensors. Brake lines just bellow that rotted and just broke yesterday. Luck ally I was only in my driveway at the time, ironic thing was I just left the shop for my safety inspection, sullivan tire derry nh 03038 should report them as well. This truck has a very severe problem with all parts on the passenger side of the motor rotting my repairs for all rotting parts 2100.00 these problems are unacceptable and should be fixed by GM . Looking and reading online I am not the only one with these problems. Seems to be happening on most all there 8 cylinder trucks and SUV.
Engine complaints in other Silverado 2500 years
Frequently asked questions
How common are engine problems on the 2004 Chevrolet Silverado 2500?
NHTSA has 36 complaints about the engine & cooling of the 2004 Chevrolet Silverado 2500, 10% of the model year's 368 complaints. The component named most often is exhaust system (6 mentions).
Is there a recall for 2004 Chevrolet Silverado 2500 engine problems?
No. NHTSA lists no engine & cooling recall for the 2004 Chevrolet Silverado 2500. 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 2500 engine problems start?
Half of the complaints with a recorded mileage happened before about 80,000 miles, and 3% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 2 fires and 0 injuries to engine & cooling 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.