Which parts fail
Components named in complaints (service brakes, ABS, rotors and pads, parking brake).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 GMC Sierra 2500 owners, lightly cleaned up (personal details are redacted by NHTSA).
I was traveling south on I-75 highway about 70 MPH, in motion, in northern michigan and had to stop fast when an accident occurred in front of me. I slammed/mashed my foot on the brake pedal only to feel it fall to the floor, the metal hydraulic line failed and I now have no brakes at all!! I began to press on the parking brake and down shift the transmission to assist in the slowing of the vehicle. I also steered around the stopped cars into the side and ditch of the road. I luckily had the right reactions but not all people do or cannot act as fast. This is a dangerous issue with this GMC Sierra 2004. Please have it recalled. I had to have the repair shop replace all the metal brake lines as they were corroded. I have never had a vehicle fail its brake lines like this. My vehicle only has 48,000 miles on it and is garage kept super clean.
I live in south east ma. Were sault is use always and it has rotted my brake lines at the ABS controll a line let go on my truck with family and my grand babies I am a heavy truck operator with a cdl so I know not to panic I got my truck stopped without a crash but if my wife was driveing or my young daughter they wouldnt be so lucky we in the saulting states should have staneless steal for safty cant be to much to ask for young lifes at stake or people who panic what should I do at the time I was in the city of taunton I was coming to a heavily traveled street in rush hour trafic the brake line to rear brakes falled because of rot on inspion I see they are all rotting and need to be repaired I dont have body rot or frame rot of any kind always car wash after storms on nice days.
My vehicle had brake lines replace two times with less than 65,000 miles because breaks stop working. Fuel line replaced under 55,000 miles because it made check engine light come on speedometer erratic,oil pressure gauge high and low,fuel gauge erratic under 65,000 miles. Loud noise from engine service technician reported the exhaust manifold bolts has broken to call a white smoke from the motor. Everything happened with consider to be low mileage in talking to GM they don't care because enough report has not been made.
Lost brakes while driving 35 MPH was able to stop and noticed brake fluid dripping from above gas tank just forward of rear axle on drivers side. New brake line was installed at GMC dealer in July 2010 after it burst going 45 MPH same problem as in July 2010 that caused an accident with property damage to my vehicle and others property after sudden complete brake failure. New line is severely corroded at each green plastic clip after only 7 months.
In the past three months the fuel lines needed replacement as they had rusted so badly that a leak formed. Yesterday while pulling my 10,000 pound boat, my brakes suddenly failed because of a leak in the line between the ABS box and the right front wheel. The catastrophic failure nearly caused me to lose control of my vehicle and boat. I was able to downshift and use by emergency brake to bring the rig to a stop.
Tl* the contact owns a 2004 GMC 2500. The contact stated that the emergency brake was inoperable. The contact mentioned that the parking brake was depressed and an abnormal noise emitted from the under carriage of the vehicle. The contact believed that the parking brake cable was fractured. The vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure. The failure mileage was 197,000.
During cold mornings (wisconsin) I start my truck and I have no power steering and soft brakes. It is my understanding that the power steering runs the brake boost. Also, it is my understanding that there is a service bulletin that says that the power steering fluid should be replaced with low/cold temp fluid. My concern is what happens if I lose power steering and brakes while I am driving.
Tl* the contact owns a 2004 GMC Sierra 2500 hd. While driving 10 MPH, the brakes failed without warning. It was diagnosed that all the brake lines needed to be replaced. The manufacturer was made aware of the failure. The approximate failure mileage was 176,395.
I was leaving a parking lot, and as I hit my brakes, there were no brakes. I limped home, using the e-brake and transmission to keep the truck under control. Upon inspection I found the front brake line rusted and leaking.
My truck is a work truck driven by an employee, I have just recently become aware of a condition regarding the instrument cluster, wherein the whole panel does not work, I was advised by the employee that this happened quite some time ago, but was never made aware. I contacted GMC but apparently, because this is considered a special policy recall (only if someone complains - and within a specified time period 7 yrs or 80,000 miles) they will not repair this defect. I never received a notice, nor was I aware of the problem within that time period. I was further informed by my worker that at the time the panel went out, the fan for the heater/air condition unit appeared to smoke and now it does not work. Here again, I have not received any recall notices for this defect either. …
Brake complaints in other Sierra 2500 years
Frequently asked questions
How common are brake problems on the 2004 GMC Sierra 2500?
NHTSA has 56 complaints about the brakes of the 2004 GMC Sierra 2500, 39% of the model year's 143 complaints. The component named most often is antilock/traction control/electronic limited slip (3 mentions).
Is there a recall for 2004 GMC Sierra 2500 brake problems?
No. NHTSA lists no brakes recall for the 2004 GMC Sierra 2500, though it has 1 recall 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 GMC Sierra 2500 brake problems start?
Half of the complaints with a recorded mileage happened before about 71,000 miles, and 6% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 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.