Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Chevrolet Silverado 3500 owners, lightly cleaned up (personal details are redacted by NHTSA).
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. …
I was coming home from work this evening and was pulling up to the garage and the brakes failed causing me to hit the garage. I was traveling less than 5 MPH. The brake pedal went all the way to the floor and the vehicle would not stop. After getting out of the vehicle found brake fluid all over the driveway. Brake lines was found to be rusted in two in several places after having a friend who is a mechanic come and look at vehicle. He found a couple lines that had exploded thru right under the drivers side seat on top the frame and another one above the fuel tank. After googling what had happened there thousands of complaints with NHTSA on this problem with GM vehicles. Why are we paying you people to try and keep the public safe. This is a very ongoing problem with GM vehicles and needs addressed promptly.
Brake line failure due to rusted & corroded brake lines resulting in costly repairs. Luckily my 2004 Chevy Silverado 3500 was stationary when brake line ruptured and I was not towing a trailer or loaded with cargo at the time of failure. The ABS pump also failed prior to line failure. My father in law had similar issues with the same model year 1500. Why does GM not use stainless brake lines for such an important safety component.
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.
All factory hard brake lines have failed due to corrosion. I've replaced the intermediate line between the master cylinder and distribution block with stainless steel 1.5 yrs ago. I just replaced the rear brake lines along the axel. Now the front brake lines have failed. In all cases the lines failed while driving and emptied the master cylinder. I do not live in the salt belt.
County road (thank goodness). Driving about 45 MPH when a lady turned off a side road in front of me. I stepped on the brake pedal to avoid a rear end collision. The brake pedal held momentarily but then went to the floor. I swerved right into the ditch and used the emergency brake to keep from striking her car in the rear. In order to get the vehicle home (approximately 3 miles), I had to use the emergency brake to stop. Could not afford to get the truck to the dealership (approximately 15 miles away in heavy suburban traffic) for diagnosis and repair. Saved up and took the truck to a local mechanic (09/2012). Mechanic ask if the truck had ever been under water. Reason for question was the brake lines, front calipers, and top forward frame were severely rusted. The brake lines rusted through causing a break failure. …
Brake lines, transmission lines and engine coolant lines all failing on 2004 Chevy Silverado 3500 hd as well as on 2003 GMC sierra 2500 hd. These problems have caused numerous amounts of time to repair and replafe, and today there was a brake failuer on the 2004 hd GMC that almost resulted in deadly accident. These lines should not have rusted and we have issues with both vehicles on the same lines. These vehicles were producted with inadequate parts for all lines on the underside of vehicle. There should not be 1,000 plus complaints from consumers regarding the rusting of these components, of which have cuased several major anmd life safety issues. The brake lines are an integral part of any vehicle and to have them rust thru to the degree of all the complaints there is obviously an issue with the compenents the manufacturer installed on these vehicles. …
I was unloading mulch from the bed of truck onto the flower beds in my yard. When I got back into the truck to move to a new spot everything was fine until I went to stop and the brake pedal went to the floor. The truck was only at an idle but the brake wouldn't even slow it down to a walking speed. The parking brake worked fine and the truck came to a stop. I put the rest of the mulching job on hold until the next day until I could figure out what had just happened and how to deal with it. The next day I checked the brake fluid and added almost a quart. When I went to move the truck the brake still went to the floor but I was ready for that and got the truck off of the grass and back out onto the driveway. That was when I saw just how bad it was leaking brake fluid and the truck is still here at my house. …
While driving my Chevy Silverado 3500 dually at approximately 50 MPH, I had so make a sudden emergency stop. My brake pedal went to the floor with virtually no stopping power for the vehicle. I swerved out of the way to avoid an accident and was very lucky. The truck went directly to the repair shop which has informed me that the brake lines are rusted through and all need to be changed. I called the Chevy support number to report this problem and ask about a recall. The rep took the last eight of my VIN number and said there is no known problem with the brakes on this vehicle. I tow heavy equipment with this truck for work, so it is an alarming safety concern for me for the brakes to suddenly not work without warning. I am lucky that nobody got killed due to this problem.
Brake complaints in other Silverado 3500 years
Frequently asked questions
How common are brake problems on the 2004 Chevrolet Silverado 3500?
NHTSA has 21 complaints about the brakes of the 2004 Chevrolet Silverado 3500, 51% of the model year's 41 complaints.
Is there a recall for 2004 Chevrolet Silverado 3500 brake problems?
No. NHTSA lists no brakes recall for the 2004 Chevrolet Silverado 3500. 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 3500 brake problems start?
Half of the complaints with a recorded mileage happened before about 68,000 miles, and 19% before 25,000 miles.
Is it dangerous?
Owners linked 4 crashes, 0 fires and 0 injuries to brakes 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.