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 owners, lightly cleaned up (personal details are redacted by NHTSA).
Tl* the contact owns a 2004 Chevrolet Silverado diesel. The contact stated that while driving approximately 40 MPH, the vehicle would overheat. The failure would only occur when traveling on flat road surfaces, uphill or when pulling a trailer. The contact would shut off the engine until the engine was cooled in order to drive the vehicle any further. In addition, the contact stated if he would drive while the vehicle was running hot, it would stall. The dealer advised the vehicle was not under recall and repairs would be at the expense of the owner. The approximate current mileage is 143,000. Updated 06/29/10 the consumer stated the vehicle overheated when towing a trailer on a long grade hill. Updated 07/06/10.
While pulling inside of the garage the consumer applied the brakes and the pedal went to the floor. The vehicle stopped by hitting the house wall. The braking before the crash caused the ABS and the engine lights to appear on the dashboard which remained on. The consumer was able to drive to the dealer for inspection. The mechanic informed the driver that the problem could not be duplicated.
Had two Chevy silverados that develop intake and water pump gasket failure on a 4.3 liter engine. Both develop coolant leak through the gasket. The latest was in November on my 2004 Chevy Silverado. Upon checking the owners manual in regards to the dexcool coolant it clearly states that this coolant will burn if spill on a hot engine. It that the case then why can it burn it the intake gasket fail and coolant is leaking in the engine. I had a 2000 Chevy Silverado with intake gasket failure and also a 2004 Chevy with gasket failure. Both vehicles I had repaired my concern it the gasket failure on these GM products vehicle that no one at Chevrolet seems to care. Both vehicles gasket failure occurred around the mid 60,000 miles range. I am concern about the failure of these gaskets that causing the coolant to leak. …
Dt: 2004 Chevrolet Silverado. The consumer stated the vehicle stalled while driving on the road. There were no warning lights that come on before this happened. This has happened every time under 50 MPH. Was able to be pull over the vehicle and restarted it immediately. The dealership could not duplicate the problem. When the vehicle was restarted it voided the chips memory. This has happened six times. The consumer had the vehicle towed to dealer,and the dealership could not find the cause of the problem. The consumer sent Chevrolet a registered letter with the information, the claim was denied. The problem started on June 29, 2005, and the last time this happened was August 19, 2005. Every time this happened the consumer called the dealership. The dealer determined there was a lower cell n the battery and replaced it but the staling problem recurred. …
I went out to leave for a meeting and started my truck. I heard a ticking noise that I had not heard prior to this morning. I opened the hood to investigate the cause of the ticking and discovered on the left bank one of the exhaust manifold bolts was missing the head. I then went around to the right bank and noticed that the exhaust manifold was broken completely about mid way of the manifold. I have owned this vehicle since it was new off the dealership and have had very little issue with it until this issue popped up. I have done some research and discovered that this is a major problem affecting Chevrolet and GM vehicles with 8 cylinder engines. This vehicle is used as a daily driver and is not used for commercial towing, nor is it used for towing on a regular basis.
About 1 month after buying a new 2004 Silverado it started surging viloently when cold. It is inconsistant, sometimes lasts for blocks. I almost got rear ended last week while tryig to control the truck. GM refuses to do anything, saying there is no diagnosis codes set and they have never heard of Silverado`s surging. They class it as a feature and say I need to feather the clutch. Feathering the clutch in traffic is a good way to get killed. This has been going on about 4 months now. I believe they know what is wrong and it is happening with more then just my one truck; but they don't want to spend the money to fix it.
After the vehicle is warm, one of the injector sleeves begins to leak diesel and oil into the crankcase, causing plumes of white and black smoke to come out of the tail pipe and causes the truck to sputter. A loud sound of a valve flapping violently also is heard. The truck has been to the dealership 4 times. Each time, they say that nothing is wrong. One dealer in monterey said that the injectors are from a 2003 model truck and are smaller than the 2004 sleeves, therefore allowing diesel and oil to leak into the crankcase. The dealership has been unwilling to correct the problem in sacramento.
Tl* the contact owns a 2004 Chevrolet Silverado. The contact stated that while driving at various speeds, the check engine light illuminated and the vehicle suddenly stalled. The contact indicated that after restarting the engine the vehicle operated as normal. The contact also indicated that the passenger side seat belt had malfunctioned and the passenger was unable to move while the seat belt was in the locked position. The vehicle was not diagnosed or repaired. The manufacturer was notified of the defect but no solution was offered. The failure mileage was 130,000.
2004.5 lly 2500hd Silverado duramax towing 1700 lund prosport in ~85 degree ambient. I was required to turn of the A/C and limit the power as the engine temp continued to climb beyond 210 and into the 235-240 degree range. This is a constant probelm with this engine under minimal load. Dealer has no fix for this truck which is still under warranty and GM keeps saying they are working on the problem. If I continued operating my truck as normal the engine would sustain overheating damage thus causing great damage to components further down the road.
2004.5 Chevy Silverado 2500 duramax overheats on several occasions to 258 deg while towing 9000lb trailer 2 times transmissions has gone to 270 deg and has gone into a protective mode while climbing a hill causing us to nearly get rear ended due to no place to pull over and extremely slow speeds took to dealer 6 times with no fix. Dealer refuses to go on road test and says vehicle is operating normally this presents and immediate danger due to slow speeds, possibility of a fire and the damage to my truck from over heating.
Related recalls
Engine and engine cooling
On certain trucks equipped with an 8.1l v8 (rpo l8-VIN g) engine have a condition in which the engine fuel rail pulse damper retainer clip May fracture resulting in inadequate retention of the damper.
Remedy: Dealers will replace the engine fuel rail pulse damper retainer clip free of charge. The recall began on August 31, 2006. Owners May contact Chevrolet at 1-800-630-2438 and GMC trucks at 1-866-996-9463.
Engine complaints in other Silverado years
Frequently asked questions
How common are engine problems on the 2004 Chevrolet Silverado?
NHTSA has 31 complaints about the engine & cooling of the 2004 Chevrolet Silverado, 5% of the model year's 622 complaints. The component named most often is engine › diesel (7 mentions).
Is there a recall for 2004 Chevrolet Silverado engine problems?
Yes — NHTSA recall 06V-289 (engine and engine cooling, Aug 3, 2006). Recall repairs are free at authorized dealers.
At what mileage do 2004 Chevrolet Silverado engine problems start?
Half of the complaints with a recorded mileage happened before about 38,000 miles, and 46% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 1 fire 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.