Which parts fail
Components named in complaints (doors, hood, frame, rust, paint and trim).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Chevrolet Silverado owners, lightly cleaned up (personal details are redacted by NHTSA).
I was driving along and had to hit the brakes immediately. I almost hit the car in front of me. I noticed I had to start putting the brakes all the way to the floor in order to stop, especially on an incline. The brake light went on and off a few times so I took it to a shop to have it looked at. They told me that my brake line blew and all the other brake lines are rusted and the truck is not safe to drive. This truck is only 11 years old, that is absolutely unacceptable that all the brake lines are rusted. The truck only has 108K miles. I called a local Chevy dealership and they quoted me 3K+ to fix it. It involved at least 20 hours of labor and they needed to lift the frame off to fix. I can not believe their are no recalls from GM or atleast them offering any help to pay for this. The dealer did not offer me any help or remedy to the situation, just wanted me to fork up 3K.
I was driving along the interstate and traffic abruptly stopped in front of me. When pressed on the brake pedal, I slowed down a little, but then the pedal went to the floor, and I rear-ended the car in front of me. After the police report was filed, I got it to a Chevy dealer and they said that one of the steel brake lines from the master cylinder to the front passenger side was rusted and had burst, spilling all of the brake fluid. The wreck damaged the front passenger side bumper, and broke the grille and the headlight support bracket.
Tl* the contact owns a 2004 Chevrolet Silverado. The contact stated that the vehicle headliner separated above the driver area, obstructing the sun visors. The vehicle was taken to a vehicle body specialist for inspection. The technician advised that the headliner border frame and sealant were defective. As a result, additional fabric and sealant was needed to reinforce the defective liner. The vehicle was not repaired. The manufacturer stated that the defective liner was not recalled. The approximate failure mileage was 65,000.
When I left our garage I noticed that the red brake system light was on. Usually my husband drives this to work but we switched vehicles because I needed to haul a trailer to help move my daughter. I have only drive this vehicle one other time so I was unfamiliar with how it handled. I noticed that I had to press hard to stop but thought that was how it handled. I drove over 120 miles with it this way, I didn't know what was wrong with it, by the time I pulled into our drive, I could barely stop the vehicle. My husband came out to release the trailer out back. He got in and said, "what's wrong with the brakes?" I said, "what do you mean?" he told me I had no brakes and I could have been killed. It was a near miss incident but I have found (as a former safety manager) that those near miss incidents often show a root cause) that in the future means something. …
Tl* the contact owns a 2004 Chevrolet Silverado. The contact was driving 45 MPH when the trailer hitch bent abnormally. The manufacturer advised that the trailer hitch could tow up 10,000 pounds and the contact was towing 4,700 pounds of pay load. The contact called the manufacturer and the manufacturer advised that the vehicle was not under warranty so they were unable to assist. The contact stated the vehicle was unsafe to drive and that the trailer could have disconnected and caused a crash due to the inaccuracy of the tow load limit. The vehicle was not repaired. The failure mileage was 79,000.
Tl* the contact owns a 2004 Chevrolet Silverado. The contact stated that the brake lines were corroded and caused the brakes to fail. The contact was attempting to stop when the brake pedal traveled to the floorboard abnormally. The contact was able to cruise to a stop. The vehicle was taken to a local mechanic where they informed the contact that the complete undercarriage of the vehicle was corroded. The contact traded in the vehicle. The failure and the current mileages were 143,000. Updated 04/30/13
Tl contact owns a 2004 Chevrolet Silverado. The contact took the vehicle to a repair shop for regular maintenance. The mechanic stated that the frame of the vehicle failed where the upper control arms attach to the front frame. As a result, he cannot use the vehicle for snow-plowing, which is its primary use. The contact believes this is a manufacturer defect, which should be replaced for free. The current and failure mileages were 112,000. Updated 11-19-08 updated 11/19/08.
Yesterday I was standing on my tailgate to strap down the lumber on my overhead rack. Suddenly the tailgate collapse down and slams into my bumper. I was shaken but not hurt. I was looking at my tailgate to determine what had just happened, I noticed that both cables that hold up the tailgate were broken apart in the center of each of them. They looked like they had rusted. When the tailgate hit the bumper it caused a dent in the back of the tailgate.
All my lines under truck rusted out brake lines shift linkage transmission lines. Brakes were the worst lines popped from rust.I keep this truck in a garage not used commercially. I'm a hospice nurse and need to get where I'm going. I keep this truck mint detailed twice a year professionally maintained every 3000 miles.[redacted]
Dt: while driving between 40-60 MPH vibration from the frame. Suspension vibration or frame beaming. It is as if there is a flat tire, the car wobbles. Very eerie feeling to be driving and this to happen. A new set of tires have been placed on front. Complained to GM,no recall but would be notified if there was. Taken to dealers who recognized this was the problem but did not do anything about.
Related recalls
Structure › Body › Tailgate › Hinge and attachments
On certain pickup trucks and sport utility vehicles, the galvanized steel tailgate support cables that retain the tailgate in the full open (horizontal) position May corrode, weaken, and eventually fracture. If both cables fractured, the tailgate would suddenly drop and strike the top surface of the rear bumper.
Remedy: Dealers will replace the cables. Interim owner notification began on April 7, 20004. The recall began on September 24, 2004, when replacement parts were available, and will continue through October 29, 2004.
Body complaints in other Silverado years
Frequently asked questions
How common are body problems on the 2004 Chevrolet Silverado?
NHTSA has 25 complaints about the body & structure of the 2004 Chevrolet Silverado, 4% of the model year's 622 complaints. The component named most often is body › tailgate › hinge and attachments (7 mentions).
Is there a recall for 2004 Chevrolet Silverado body problems?
Yes — NHTSA recall 04V-129 (hinge and attachments, Mar 17, 2004). Recall repairs are free at authorized dealers.
At what mileage do 2004 Chevrolet Silverado body problems start?
Half of the complaints with a recorded mileage happened before about 40,000 miles, and 40% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 0 fires and 3 injuries to body & structure 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.