Most common 2004 Chevrolet Silverado 3500 problems
Share of the 41 complaints; one complaint can involve more than one system. "~" is the median mileage when the problem started.
Chevrolet Silverado 3500 complaints by model year
Best Silverado 3500 years: 2014, 2017, 2012. Years to avoid: 2024, 2025, 2021, 2020, 2022. Compare all years →
What 2004 Chevrolet Silverado 3500 owners say
Brakes all 21 →
2 problems: 1- while driving with no warning the brakes failed. After coasting to a stop I noticed a brake line had ruptured at the frame rail under driver area. I was able to crimp brake line with a pair of vice grip pliers and move truck to a safe location for repair. I believe the brake lines used on these trucks to be of such inferior quality that sudden failure is a common occurrence. 2- my truck has dual tanks for diesel fuel and they have worked sporadically for years. I did not see this as a safety issue as much as an inconvenience. However while my truck was idling on a hot summer day I noticed diesel fuel dripping out of the front tank filler cap. Apparently the pump that pumps the fuel from the rear tank to the front tank was receiving a signal to pump even though the front tank was completely filled. It was continuing to pump and leaking the fuel out the filler neck. …
In March while driving my 2004 Chevy 3500 diesel truck the brake warning lights inside the cab lit up and the brake pedal was feeling spongy. I took it into classic auto group mentor for service. A wheel bearing was replaced along with a few other items and I was told that it was good to go. I picked it up. The brake pedal was still spongy and the warning lights were still on. On April 22, I returned to the classic auto group Chevy service to again have the brakes serviced. They billed me $1400.00 to change a valve, a module and some screws. The brakes now go all the way down to the floor when depressed with the motor running. There is no effective braking ability. With no effective braking the warning lights are not lit up. Classic auto group Chevy in mentor says that this is normal. This is not how the brakes worked before the warning lights came on. …
Fuel & propulsion system
2 problems: 1- while driving with no warning the brakes failed. After coasting to a stop I noticed a brake line had ruptured at the frame rail under driver area. I was able to crimp brake line with a pair of vice grip pliers and move truck to a safe location for repair. I believe the brake lines used on these trucks to be of such inferior quality that sudden failure is a common occurrence. 2- my truck has dual tanks for diesel fuel and they have worked sporadically for years. I did not see this as a safety issue as much as an inconvenience. However while my truck was idling on a hot summer day I noticed diesel fuel dripping out of the front tank filler cap. Apparently the pump that pumps the fuel from the rear tank to the front tank was receiving a signal to pump even though the front tank was completely filled. It was continuing to pump and leaking the fuel out the filler neck. …
Tl contact owns a 2004 Chevrolet Silverado 3500. When there is half of a tank of fuel in the vehicle, it automatically shuts off. Additionally, the brake pedal extended to the floor when it was depressed, which caused a crash. A police report was filed. General motors stated that nothing could be done. The speed was unknown. The failure mileage was 15,000 and current mileage was 24,750.
Engine & cooling
Ticking under hood. Exhaust leak due to broken exhaust manifold bolt passenger side near firewall. Tried to loosen other bolts, 3 more broke. Truck has very low miles, 8.1l motor. Internet shows thousands of same issues. Bolts used are very thin for what they do.
In January 2004, I bought a new Chevy 3500 duramax diesel truck. Since March 2005, I have had to have the injectors replaced a total of 6 times. Now at 202,000 the injectors need replaced again. Chevy will not help out on this problem. I have read that everyone should file a complaint with this department so that this can be investigated. In November 2011, someone was told there were not complaints. Being a Chevy owner with these injector problems, I am writing to complain. Hopefully, this department will conduct the investigation and help all the other people with this problem get a response from Chevy to do something. These trucks are not cheap and just because we use our trucks and put miles on them, and they have repeated failures, we should not have to bear the burden. This problem with my truck is in the design. How many people replace injectors every 30-40K miles? …
Frequently asked questions
Is the 2004 Chevrolet Silverado 3500 a good car?
Based on 41 owner complaints filed with NHTSA, the 2004 Silverado 3500 rates average: about as many complaints as a typical year of the Silverado 3500 at the same age. Complaint counts don't account for sales volume or individual maintenance, so have any used car inspected before buying.
What is the most common problem with the 2004 Chevrolet Silverado 3500?
The brakes — 21 complaints, 51% of all complaints for this model year. Next are the fuel & propulsion system (7) and engine & cooling (6).
How many recalls does the 2004 Chevrolet Silverado 3500 have?
NHTSA lists no recalls for the 2004 Chevrolet Silverado 3500. You can still confirm with your VIN using our VIN recall check.
What are the best and worst years of the Chevrolet Silverado 3500?
The best years by complaints, compared at the same age, are 2014, 2017 and 2012. Years to avoid or approach with caution: 2024, 2025, 2021, 2020 and 2022. See the full Chevrolet Silverado 3500 years comparison.
At what mileage do 2004 Chevrolet Silverado 3500 problems happen?
The median mileage reported in complaints is about 50,000 miles; 49% of problems with a recorded mileage started before 50,000 miles.
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.