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 2500 owners, lightly cleaned up (personal details are redacted by NHTSA).
I have had a complete brake job because all of the lines rusted out and failed as I was driving. Fortunately, I was able to use the emergency brake to stop safely. I spent rough.y $3,000 to get this repaired. Now the fuel lines, fuel cooler and everything attached has rusted out to the point that it is going to be an additiona $2,500 to repair this. Also, the complete under carriage and rear end has rusted to the point that I am expecting it to fail at any time. This is not only a dangerous situation, but is extremely costly to the consumer, me. When the brakes failed, I was driving on a street approaching a busy intersection. With no warning at all, the pedal went to the floor and I had no brakes. The repair facility mechanic said he has never seen a system so bad. I keep the vehicle in a garage and have washed the under carriage in the winter to keep road salt from accumulating.
My 2004 Chevrolet Silverado 2500 hd has had multiple brake issues. The brake lines and fuel line have rusted out. Approximately 2 years ago I had break line rust out and they where replaced. They have rusted out again.my truck is very well cared for and is clean and not driven often. I have had multiply conversations with general motors hotline and have not got anywhere. I have researched the web and see this is a big problem with general motors products.my truck now has about 70,000 miles and is still very clean and very well kept. I hoping some one could look out for the consumer and request they have a recall of there product before some one is injured or killed.
Tl* the contact owns a 2004 Chevrolet Silverado 2500 hd. While driving he saw smoke coming from the tail pipe, and then he smelled a burning odor. The vehicle was taken to the dealer for inspection. The technician concluded that the thermostats are not allowing the vehicle to achieve operating temperature and injectors 5, 6, 1 are defective. The repair will be performed at the owners expense. The failure mileage was 102000. The current mileage was 103000.
Check engine light came on and "low engine power" flashed where the odometer is. This caused the RPM's not to go over 2800. Code reader claims o2 sensors or throttle control module or catalytic convertor issues. We discovered it was none of the above. To fix problem change 3 relays located under hood in fuse box. Relay #8864. Then clear codes, should fix issue unless code persists. Relays will cause a fire if not changed out asap.
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
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 …
While driving in heavy denver, colorado traffic late afternoon hours of 07/18/2014, my 2004 Chevrolet Silverado 2500 hd, duramax lly had a "significant reduction of engine power". GM was aware of this as early as August 17, 2009, as per their bulletin # 09-06-04-034. This bulletin states this May be caused by the fuel injector wire harness rubbing against the bracket and chafing the wire insulation. This occurred on my vehicle causing one wire to short against the bracket. This immediately shut down the affected cylinder bank resulting in an immediate reduction of engine power. I feel this could be a safety concern. Fortunately I was able to get to the side of the roadway without incident. I have sent three emails to [redacted]
2004 Chevy Silverado 2500 hd with fuel injectors problems customer states that they have had the fuel injectors replaced three times and wants GM to stand behind it's product** on 8/01/06 the check engine light illuminated and the truck began to emit white smoke. The consumer took the vehicle to the dealer it was noted that the fuel injectors had high balance rates so all were replaced. In April the gauges all shut down and the truck stopped running in the desert in 100 degree weather and were informed by a second dealer fuel injectors needed to be replaced yet again. The consumer stated was preparing for a trip decided to take the vehicle back into the dealer to have the truck checked and behold a third time the fuel injectors needed to be replaced. The consumer stated would like vehicle fixed.
I was driving down the freeway going 70 MPH on my way to work during rush hour traffic in the fast lane. All of a sudden I lost power and the truck started slowing down quickly. I immediately had to try to get over and get off the freeway so that I would not get run over, which is not an easy thing to have a vehicle on the freeway during rush hour that will not go over 15 MPH. This is not very safe and I could have easily have caused an accident by cars trying to swerve around my vehicle that would not accelerate. The problem was the #7 fuel injector connector, which has been replaced and I do have the old part. I am not the only one this has happened to and this should not be happening to a two year old vehicle. When this part breaks, I feel people are at risk and this should be taken care of.
At approx 65,000 miles my speedometer stopped working along with other gauges in the instrument panel. GM refused to fix the problem. When I had 80,000 miles GM offered to fix the defect only on vehicles with less than 70,000 miles. They refused to correct the defect on my vehicle. The dealer estimates the cost to fix this defect at approx $450.00 I now have approx 105,000 miles and continue to drive without a working speedometer. This vehicle and many with this same defect is used for towing. GM has put profit ahead of safety and customer satisfaction. The ntsb has continued to allow thousands of vehicles to operate unsafely with this well known and documented defect by failing to force GM to recall these vehicles many of which were still being manufacture after the defect was discovered.
Fuel System complaints in other Silverado 2500 years
Frequently asked questions
How common are fuel system problems on the 2004 Chevrolet Silverado 2500?
NHTSA has 26 complaints about the fuel & propulsion system of the 2004 Chevrolet Silverado 2500, 7% of the model year's 368 complaints. The component named most often is fuel injection system (2 mentions).
Is there a recall for 2004 Chevrolet Silverado 2500 fuel system problems?
No. NHTSA lists no fuel & propulsion system 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 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 66,000 miles, and 8% 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.