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 Trailblazer owners, lightly cleaned up (personal details are redacted by NHTSA).
I own a 2004 Chevrolet Trailblazer ext and just like the thousands of others mine has a defective gas tank filler on the top of the tank. It's a known bad part feom the factory. Mine has had a hole for a while now. It can literally leak over 10 gallons of gas a day if you fill the tank to full. Even if you don't the smell of gas in and around the vehicle is terrible. My check engine light is on because of it. It runs like crap because of it. What's more dangerous than spilling gas everywhere you go!? Some people have had Chevy pay for the repairs on there 2004 Trailblazer. Look it shouldn't matter what your VIN# is or how many miles at this point (I just hit 150,000) the gas tanks on these vehicles are faulty, they're dangerous, they're exspensive. I surely dont have $800-$1500 laying around to fix a part that is known and proven to be bad. …
Smelled gas and noticed puddle under vehicle when parked. Checked online and found this seems to be a common problem for this vehicle and was worried because this seems to be a safety issue. Contacted Chevrolet about it and was told to take to dealer to have inspected for any damage to vehicle. I was charged $49.73 to be told that I had a fuel leak and to repair it I would be charged $1897.00 even though Chevrolet has issued a service bulletin #05012 for this very issue and that it can be repaired for no charge but they would only cover for 10 yrs. Or 120,000 miles. But since I am a little over on both items they will cover nothing and want me to pay the entire amount to which I feel this is very unfair as this is a common issue with this vehicle and miles should not be an issue for a defective part and since this is a safety issue.
Tl* the contact owns a 2004 Chevrolet Trailblazer. The contact stated the he noticed a fuel odor emitting from underneath the driver's side of the vehicle. The contact also stated that the fuel mileage had also decreased when driving the vehicle. The contact took the vehicle to have an EVAP smoke test performed on his vehicle. The result of the test discovered that a crack had formed on the fuel neck that connects to the fuel tank, which was the cause of the failure. The contact then spoke with j.b.a. Chevrolet (7327 ritchie hwy, glen burnie, md 21061) where he was informed that there were no recalls on the vehicle for the failure. The manufacturer was notified of the failure. The vehicle was not repaired. The failure mileage was approximately 126,432.
Tl* the contact owns a 2004 Chevrolet Trailblazer. The contact stated that the service engine light warning indicator illuminated and there was an abnormal fuel odor in the vehicle. The vehicle was taken to a dealer where it was diagnosed that the vehicle needed a fuel cap. The vehicle was repaired however upon further inspection the technician informed the contact that the fuel hose had a tear and the fuel pump module would need to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The contact referenced NHTSA campaign: 09V419000 ( fuel system, gasoline) as a possible solution to the failure however the VIN was not included. The failure mileage was approximately 162,000.
My vehicle is in the GM special coverage adjustment program number 07099 and is under the GM spl coverage pgm update 14423. I was notified that the icv could fracture and create an 'engine service soon' light. That light was activated in February. I took it in, it's the icv. They said they'd replace the fuel tank as soon as they could get parts. They still don't have the replacement -- and say it could be May or June. Meanwhile the 'check engine' light could be on for icv -- or it could be another problem. With dripping fuel out in the open, it's a safety hazard -can't be used on a trip and can't be sold/traded as it's defective.
Tl* the contact owns a 2004 Chevrolet Trailblazer. While driving 45 MPH, the contact detected a fuel odor coming through the vents. The contact mentioned that the check engine indicator illuminated prior to the failure. The contact also stated that the instrument panel did not illuminate and the speedometer did not operate. The vehicle was taken to an independent mechanic where the contact was informed that the fuel pressure regulator needed to be replaced. The vehicle was not repaired. The dealer and manufacturer were not made aware of the failures. The failure mileage was 153,000.
Tl* the contact owns a 2004 Chevrolet Trailblazer. When the vehicle was started, a strong odor of fuel was present. The vehicle was driven to the dealer where it was diagnosed that there was a failure with the fuel tank. The vehicle was kept at the dealer for four weeks. The dealer stated that the part needed to repair the vehicle was not available and needed to be ordered. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 46,500. ...updated 07/13/16 .....updated 08/11/16
My 2004 Trailblazer kicked into full speed while I was traveling in an icy road at 20 MPH. It automatically switched to 4 wheel drive, spun at a 90 deg. Went into a deep ditch, spun back straight and headed up the ditch, again full speed, into a culvert and totaled the vehicle. Both air bag sensors were knocked off the vehicle and neither one opened. I was not injured. Shook up a little. Traveling alone and coming home from church on a Sunday morning at noon.
Tl* the contact owns a 2004 Chevrolet Trailblazer. The contact stated that there was an odor of fuel was present inside and outside the vehicle. The vehicle was taken to the dealer, who diagnosed that the fuel pump and the fuel lines were damaged which were caused by a faulty inlet check valve . The vehicle was not repaired. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was 165,000.
Tl* the contact owns a 2004 Chevrolet Trailblazer. While the vehicle was parked, it had a strong odor of fuel fumes and the check engine warning light illuminated. The contact stated that there were also a few drops of fuel on the garage floor under the vehicle. The vehicle was taken to a dealer where it could not be diagnosed. The manufacturer was made aware of the failure. The failure mileage was 134,000.
NHTSA investigations
Fuel pump module leaks gasoline
During the course of this ea investigation, odi observed that the majority of the complaints (88%) and warranty claims (94%) were reported for vehicles that are registered for use in the salt belt region of the us.this area includes 20 states in the northeast, mid atlantic and the midwest regions and the district of columbia.consumers in the salt belt region reported to odi that they could smell fuel vapors in their…
Fuel System complaints in other Trailblazer years
Frequently asked questions
How common are fuel system problems on the 2004 Chevrolet Trailblazer?
NHTSA has 148 complaints about the fuel & propulsion system of the 2004 Chevrolet Trailblazer, 14% of the model year's 1,081 complaints. The component named most often is storage › tank assembly › filler pipe and cap (10 mentions).
Is there a recall for 2004 Chevrolet Trailblazer fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2004 Chevrolet Trailblazer, though it has 2 recalls for other components. 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 Trailblazer fuel system problems start?
Half of the complaints with a recorded mileage happened before about 83,000 miles, and 6% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 0 fires and 3 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.