Most common 2004 GMC Sierra 3500 problems
Share of the 24 complaints; one complaint can involve more than one system. "~" is the median mileage when the problem started.
GMC Sierra 3500 complaints by model year
Best Sierra 3500 years: 2012, 2014, 2013. Years to avoid: 2024, 2020, 2023, 2025, 2022. Compare all years →
What 2004 GMC Sierra 3500 owners say
Brakes
I picked my stepdaughter at school and at the stoplight to leave the school there were no brakes. I used the curb to slow the truck enough to the lights to change. It was not a busy time and students were not present otherwise this would have been a disaster. I drove the truck home with flashers very slowly home on a back road downshifting and relying in the allison transmission. When I reached home the light came on to service brakes. That was obvious already. This is a 1 ton dually that usually hauls skid loads, paving bricks, etc. I could not imagine what would have happened if the brake lines blew during this time. There is a small rusted pin sized whole in the front brake line that runs on top of the truck frame. I still have brake fluid in the reservoir, but not enough to stop the truck. There was not warning and those lines are tucked up on the frame out of site for inspection. …
On highway multi-lane, heavy traffic ahead, suddenly slowed and a lot of lane changing going on as some debris was ejected from truck onto roadway. Applied brakes, application had little effect. Stood on the brakes, butt out of the seat standing on the brakes, truck veered off to right severely while ant lock pulsed. Fortunately traffic got out of the way and escaped harm. Exited highway inspected vehicle. Upon exiting the truck found puddle of brake fluid on ground under driver's seat. Brake lines leaking. Sever rust throughout the brake system. Replacement of all brake lines required. This was very close to crash, only the rapid reflexes of the guy next to me averted an accident. Note, repair shop tells me that (and has shown me) all the brake lines must be replaced. …
Electrical system
The fan for the heater doesnt work on all speeds properly, stopped working entirely
Tl contact owns a 2004 GMC Sierra 3500. The contact stated that the speedometer stopped working. The warning indicators were that the speedometer displayed faster speeds than what was actually being driven. As a result, the alternator gauge has failed. He took the vehicle to the dealer and they stated that he would be responsible for the repair costs because the vehicle had over 75,000 miles. The manufacturer sent the contact a letter that stated they were aware of the defect; however, nothing could be done. The estimated repair costs would be $425. The failure mileage was 65,000 and current mileage was 114,000. Updated 5/6/08 updated 05/06/08
Fuel & propulsion system
Tl contact owns a 2004 GMC Sierra dormax diesel (na). The contact stated that the fuel injectors produce white smoke. Ocassionally, the vehicle becomes difficult to start. The contact serviced the injectors every 10,000 miles, but the failure is persistent. The vehicle was taken to the dealer and they kept replacing the injectors, but to no avail. The failure mileage was 30,000.
Tl* the contact owns a 2004 GMC Sierra 3500 hd. The contact stated that there was a large puddle of unknown fluids under the vehicle. After inspecting the vehicle, the contact discovered that the fuel line was severely corroded and causing diesel fuel to leak. The vehicle was taken to a dealer where they advised the contact that the fuel line needed to be replaced due to the corrosion. The vehicle was not repaired and the manufacturer was not contacted in regards to the failure. The failure mileage was approximately 117,000. Updated 02/03/12 the consumer stated the vehicle has since been repaired. The brake lines were corroded as well. Updated 02/08/12
Frequently asked questions
Is the 2004 GMC Sierra 3500 a good car?
Based on 24 owner complaints filed with NHTSA, the 2004 Sierra 3500 rates use caution: 1.4× as many complaints as a typical year of the Sierra 3500 at the same age. It is one of the Sierra 3500 years we suggest avoiding. Complaint counts don't account for sales volume or individual maintenance, so have any used car inspected before buying.
What is the most common problem with the 2004 GMC Sierra 3500?
The brakes — 14 complaints, 58% of all complaints for this model year, most often about power assist. Next are the electrical system (5) and fuel & propulsion system (4).
How many recalls does the 2004 GMC Sierra 3500 have?
NHTSA lists no recalls for the 2004 GMC Sierra 3500. You can still confirm with your VIN using our VIN recall check.
What are the best and worst years of the GMC Sierra 3500?
The best years by complaints, compared at the same age, are 2012, 2014 and 2013. Years to avoid or approach with caution: 2024, 2020, 2023, 2025 and 2022. See the full GMC Sierra 3500 years comparison.
At what mileage do 2004 GMC Sierra 3500 problems happen?
The median mileage reported in complaints is about 87,000 miles; 27% of problems with a recorded mileage started before 50,000 miles.
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.