2004 Chevrolet Silverado 2500 Problems
- Complaints
- 368filed with NHTSA
- Median mileage
- 73,800miles, 335 complaints with mileage
- Recalls
- 0campaigns on record
- Trend
- FallingComplaints filed in the last 3 full calendar years are at least 25% lower than in the 3 years before.
- NHTSA crash rating
- —overall rating starts with 2011 models
- EPA fuel economy
- 10 mpgcombined, 6.0L 8-cyl · natural gas RWD · 9 city / 11 hwy
Sources: NHTSA records for the 2004 Chevrolet Silverado 2500 (complaints, recalls, investigations), EPA fuel economy. Report an error
What owners report
Owners of the 2004 Chevrolet Silverado 2500 report brake problems more than anything else, and most of those complaints center on steel brake lines that rust through and let the pedal fall to the floor. Instrument cluster failures, especially a speedometer or gauge that reads wrong or quits, are the second most common theme. Many of these reports involve trucks that were already several years old, with failures appearing anywhere from about 50,000 to 150,000 miles.
- Brakes
Rusted-through brake lines, pedal to the floor
- 161 complaints (44%)
- median 81,869 mi at 9.5 yrs old (158 state mileage)
- 13 mention a crash, fire or injury
- owner-quoted repair $1,604 (median of 22 quotes)
- filed 2006–2023
Owners describe the brake pedal sinking to the floor, sometimes with no warning, while driving, braking for a turn, or pulling a trailer. Shops and dealers who inspect the truck typically find the steel lines corroded, with one line burst or leaking under the driver's door or along the frame rail, and often recommend replacing every brake line. Several owners say they stopped with the parking brake or trailer brakes, and some mention fuel lines showing the same corrosion. Mostly reported between roughly 50,000 and 150,000 miles, on trucks that had spent years in road-salt climates; a few were under 50,000 miles.
What to check: Have the brake lines inspected from the master cylinder back to the rear axle, paying attention to the sections under the driver's door and along the frame rail. Ask whether the lines have been replaced, and with what material.
2 excerpts from owner complaints in NHTSA records
“The brake line to the rear brakes failed due to rust (ruptured). This is the third chevy truck, of this generation, that I have owned; all three have experienced this failure. All three failed with no warning. I cannot believe people have not been killed; I was left with very little effective braking in all three events.”
NHTSA complaint #10577501, filed 2014-04, 104,000 miles“After placing my foot on the brake to shift into gear the pedal went to the floor and I got a brake warning light. I opened the master cylinder cap and saw no brake fluid. I filled it up and the level kept dropping so I looked under the car and saw a puddle of fluid. I traced the fluid to the metal brake lines and noticed that they were all massively corroded to the point of having flakes of metal peeling off the lines. …”
NHTSA complaint #10557074, filed 2013-12, 78,536 miles - Electrical system
Speedometer and dashboard gauges read wrong or fail
- 84 complaints (23%)
- median 65,500 mi at 4.6 yrs old (72 state mileage)
- 1 mention a crash, fire or injury
- owner-quoted repair $500 (median of 16 quotes)
- filed 2006–2017
Complaints describe the speedometer jumping to high readings while parked, freezing, or dropping to zero, and sometimes other gauges misbehaving too. Dealers generally identified the instrument cluster as the cause and quoted several hundred dollars to replace or repair it, with some owners told coverage depended on mileage. A few owners report the cluster making noise or smoke coming from the dash. Often reported somewhere between about 40,000 and 100,000 miles, with some failures noted at higher mileage.
What to check: Check that the speedometer and other gauges read sensibly at idle and at speed, and ask whether the instrument cluster has been repaired or replaced.
2 excerpts from owner complaints in NHTSA records
“I have a 2004 silverado 2500hd(c/k) with 51,000+ miles. This problem has been occurring for several weeks and just started as I was driving the vehicle on the highway. The speedometer operates erratically by showing various speeds such as 80 MPH while I am driving 25 MPH or shown 120 MPH while I am stopped. At time it might work properly but then jump to 60 MPH while I am driving 20 or while I am sitting still. …”
NHTSA complaint #10179194, filed 2007-01, 50,500 miles“Not only have I had problems with the emergency brake sticking and rear brakes but the brakes and fuel lines where it makes a turn around the frame just under the driver side foot well are scary rusted as if they used a cheap steel for the lines. I was a chevy dealer mechanic in the 1980s and know what im looking at. I havent had the lines blow out yet but im sure they will. Also all the gauges in the instrument cluster exept the odometer and gas gauge and the fan controls do not work.”
NHTSA complaint #10433077, filed 2011-10, 70,000 miles - Fuel system
Rough running or loss of power from fuel injectors
- 30 complaints (8%)
- median 89,500 mi at 6.8 yrs old (28 state mileage)
- 2 mention a crash, fire or injury
- owner-quoted repair $2,150 (median of 6 quotes)
- filed 2006–2018
Owners of diesel trucks describe smoke, failed emissions tests, and sudden loss of power or reduced power, which shops attributed to injectors or injector wiring rather than the injectors alone. Some owners mention a manufacturer warranty on injectors that was limited by time or mileage, and one owner traced the power loss to a chafed injector harness. Gasoline owners also report fuel tank leaks and repeated check-engine lights from the fuel system. Reported from roughly 60,000 miles upward, on trucks used for towing and highway driving.
What to check: On a diesel, ask about injector replacement history and any warranty work, and watch for smoke or a check-engine light on a test drive; on a gas truck, look for fuel smells or leaks around the tank.
2 excerpts from owner complaints in NHTSA records
“While driving in heavy denver, colorado traffic late afternoon hours of 07/18/2014, my 2004 Chevrolet SILVERADO 2500 hd, duramax lly had a significant reduction of engine power . Gm was aware of this as early as august 17, 2009, as per their bulletin # 09-06-04-034. This bulletin states this may be caused by the fuel injector wire harness rubbing against the bracket and chafing the wire insulation. This occurred on my vehicle causing one wire to short against the bracket. …”
NHTSA complaint #10627442, filed 2014-08, 160,000 miles“I was driving down the freeway going 70 MPH on my way to work during rush hour traffic in the fast lane. All of a sudden I lost power and the truck started slowing down quickly. I immediately had to try to get over and get off the freeway so that I would not get run over, which is not an easy thing to have a vehicle on the freeway during rush hour that will not go over 15 MPH. This is not very safe and I could have easily have caused an accident by cars trying to swerve around my vehicle that would not accelerate. …”
NHTSA complaint #10166281, filed 2006-08, 69,407 miles - Brakes
Hydro-Boost brake assist leaks or stops working
- 14 complaints (4%)
- median 81,050 mi at 7.0 yrs old (14 state mileage)
- 1 mention a crash, fire or injury
- filed 2006–2020
Owners describe a hard brake pedal, poor stopping, and stiff steering together, which shops traced to the hydro-boost unit leaking power steering fluid. In some cases the booster was found to need replacement; one owner reported the unit failed again after brake lines and the master cylinder had already been replaced. Usually reported on higher-mileage trucks, from about 100,000 miles upward.
What to check: Check the power steering fluid level and look for fluid weeping around the hydro-boost unit at the firewall, and ask whether it has ever been replaced.
2 excerpts from owner complaints in NHTSA records
“(1) I was in a tight turn. I had just hauled 2 tons of feed from a feed mill 30 miles away. (2) the power steering and brakes both stopped working suddenly and with no warning. I had no control over my vehicle and had to run into a fence post to stop it. Had it happened a few minutes earlier while I was on a highway, someone could have been seriously injured or killed. The truck was completely uncontrollable. (3 vehicle was towed to dealer. After two days of testing, no solution has been found.”
NHTSA complaint #10165893, filed 2006-08, 30,450 miles“Hydro boost has failed. It was discovered by gardnerville auto in gardnerville, nevada . On wednesday 1/15/2020. I contacted general motors and they said there no recalls on this vehicle. They showed old recalls on lighting and power steering but nothing on the hydro boost. The garage shows three different recalls on the hydro boost, two of which were reported by ntsb.”
NHTSA complaint #11300497, filed 2020-01, 185,000 miles
Buying note. Brake line corrosion is the item to look at most closely on this model year, so have the lines inspected before purchase and budget for replacement if they are original. Also verify the instrument cluster works correctly and check for fluid leaks around the hydro-boost unit.
Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.
NHTSA recorded 368 consumer complaints for the 2004 Chevrolet Silverado 2500. 335 of the complaints include a mileage, and 24% of those were filed for vehicles with under 50,000 miles; the median is 73,800 miles. Of all complaints, 19 involved a crash, 10 a fire, 10 an injury, 2 a death, according to the filers. NHTSA lists 0 recall campaigns and 427 technical service bulletins for this model year.
Not compared (before 2008). Model years 2008–2023 of the same vehicle that have at least 25 complaints are compared, and a model needs at least 3 of them.
Which parts are reported most
Complaints can name more than one part, so the counts add up to more than the total. Select a part to see its complaints, recalls and bulletins.
- Brakes168 46%
- Electrical system105 29%
- Fuel system26 7.1%
- Engine cooling23 6.3%
- Steering16 4.3%
- Transmission and drivetrain15 4.1%
- Engine14 3.8%
- Suspension12 3.3%
- Wheels9 2.5%
- Vehicle speed control6 1.6%
Also reported: Other or unknown (5), Tires (5), Air bags (4), Body and structure (4), Visibility (wipers, defrost, mirrors) (4), Equipment (2), Exterior lighting (2), Latches, locks and linkages (1).
Example complaints
Brakes: “Driving home from my wife's parents hose on rt 40, the traffic light changed. And when I depressed the brake pedal, the pedal went to the floor. I started to pump the brake pedal, and was lucky to stop my truck before I went throught the light. I was able to nurse my truck home. The next day I called my mechanic and had the problem taken care of.”
NHTSA complaint #10579366, filed 2014-04, 99,458 milesElectrical system: “Driving on the interstate at 65-70 MPH truck shut off no power steering no brakes showing reduced engine power almost got into a wreck with my 2 year old son and 70 year old grandmother...I still owe $10,000 on this hunk of crap...it went away after a broken wire was fixed....but as I sit here in my truck at 3 am because I had to move it I started it up and once again reduced engine power...just so frustrating”
NHTSA complaint #10953964, filed 2017-02, 142,000 milesFuel system: “I have had a complete brake job because all of the lines rusted out and failed as I was driving. Fortunately, I was able to use the emergency brake to stop safely. I spent rough.y $3,000 to get this repaired. Now the fuel lines, fuel cooler and everything attached has rusted out to the point that it is going to be an additiona $2,500 to repair this. Also, the complete under carriage and rear end has rusted to the point that I am expecting it to fail at any time. This is not only a dangerous situation, but is extremely costly to the consumer, me. …”
NHTSA complaint #11102632, filed 2018-06, 42,000 milesEngine cooling: “The exhaust manifold bolts are broken on my 2004 Chevrolet 2500 hd truck. They are also broken on my sons 2004 gmc 2500 hd and my brothers 2005 gmc 2500hd. Something is wrong with that and something should be done before they catch fire.”
NHTSA complaint #10396693, filed 2011-04, 90,000 milesMileage when problems were reported
24% of the 335 complaints with a mileage were filed for vehicles with under 50,000 miles; the middle half falls between 50,000 and 104,000 miles.
Complaints by year filed
Trend: falling. Complaints filed in the last 3 full calendar years are at least 25% lower than in the 3 years before.
Fuel economy and running cost
EPA ratings for each 2004 Chevrolet Silverado 2500 version. Annual fuel cost is the EPA's estimate at its current fuel prices for 15,000 miles a year (55% city driving).
| Version | Engine | Transmission | City | Hwy | Comb. | Fuel / yr |
|---|---|---|---|---|---|---|
| Silverado 2500 HD 2WD CNG | 6.0L 8-cyl · natural gas | 4-speed automatic | 9 | 11 | 10 | $4,600 |
Source: U.S. EPA and Department of Energy, fueleconomy.gov. Ratings are for comparing vehicles; real-world mileage varies with driving and conditions.
Recalls and investigations
NHTSA lists no recall campaigns for the 2004 Chevrolet Silverado 2500 in the data used here. A recall can apply to some vehicles of a model year and not others, so check a specific vehicle by VIN at nhtsa.gov/recalls.
Technical service bulletins
TSBs are manufacturer notes to dealers about known repair procedures. They are not recalls and do not by themselves mean a vehicle has a fault. 427 on record; the latest 10 are shown.
- 11020816Jul 18, 2025Other or unknown. This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.
- 11017252Mar 28, 2025Electrical system, Other or unknown. This service bulletin provides information for dealers/technicians on OnStar Module 2G Sunset Information.
- 11014455Feb 20, 2025Other or unknown. This Preliminary Information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get…
- 11012907Dec 18, 2024Engine. This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.
- 11010544Oct 7, 2024Engine. This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.
- 11007208Sep 6, 2024Other or unknown. This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires…
- 11006621Aug 26, 2024Electrical system. Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need…
- 11006421Jul 24, 2024Transmission and drivetrain. GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging…
- 11004761Jun 28, 2024Fuel system, Engine. This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with…
- 11004557Jun 17, 2024Other or unknown. This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim.
Other model years of the Chevrolet Silverado 2500
| Year | Complaints | Median mi | Recalls | Crash ★ | MPG | Score (50 = typical) | Trend |
|---|---|---|---|---|---|---|---|
| 2026 | 13 | 5,100 | 2 | — | — | — | Too new |
| 2025 | 30 | 15,250 | 1 | — | — | Too new to compare | Too new |
| 2024 | 143 | 18,400 | 4 | — | — | Too new to compare | Too new |
| 2023 | 47 | 47,000 | 1 | — | — | 25 · Fewer | Too new |
| 2022 | 97 | 37,500 | 3 | — | — | 62 · Typical | Rising |
| 2021 | 89 | 39,500 | 6 | — | — | 70 · More | Rising |
| 2020 | 109 | 25,000 | 10 | — | — | 93 · More | Rising |
| 2019 | 74 | 12,025 | 7 | 4 | — | 77 · More | Stable |
| 2018 | 53 | 24,138 | 5 | 4 | — | 48 · Typical | Stable |
| 2017 | 54 | 21,000 | 5 | 4 | — | 50 · Typical | Stable |
| 2016 | 123 | 35,000 | 6 | 4 | — | 77 · More | Falling |
| 2015 | 179 | 44,000 | 6 | 3–4 | — | 91 · More | Stable |
| 2014 | 40 | 70,900 | 2 | 2–4 | — | 0 · Fewer | Rising |
| 2013 | 51 | 74,742 | 3 | 2–4 | — | 0 · Fewer | Falling |
| 2012 | 53 | 72,000 | 3 | 3–4 | — | 0 · Fewer | Stable |
| 2011 | 104 | 72,000 | 4 | — | — | 42 · Typical | Falling |
| 2010 | 21 | 98,000 | 5 | — | — | — | Falling |
| 2009 | 61 | 59,000 | 5 | — | — | 50 · Typical | Falling |
| 2008 | 191 | 56,000 | 4 | — | — | 60 · Typical | Falling |
| 2007 | 204 | 57,230 | 3 | — | — | Not compared (before 2008) | Falling |
| 2006 | 178 | 52,000 | 0 | — | — | Not compared (before 2008) | Stable |
| 2005 | 269 | 63,000 | 0 | — | 11 | Not compared (before 2008) | Falling |
| 2004 | 368 | 73,800 | 0 | — | 10 | Not compared (before 2008) | Falling |
| 2003 | 449 | 83,020 | 0 | — | 10 | Not compared (before 2008) | Falling |
| 2002 | 351 | 84,118 | 1 | — | 11 | Not compared (before 2008) | Falling |
| 2001 | 388 | 75,500 | 1 | — | — | Not compared (before 2008) | Stable |
| 2000 | 132 | 85,500 | 1 | — | 15 | Not compared (before 2008) | Rising |
| 1999 | 81 | 94,000 | 0 | — | 15 | Not compared (before 2008) | Stable |
| 1998 | 73 | 82,274 | 0 | — | — | Not compared (before 2008) | Stable |
| 1997 | 64 | 88,500 | 0 | — | — | Not compared (before 2008) | Stable |
All Chevrolet Silverado 2500 model years · Best and worst years by complaints
Frequently asked questions
What are the most common problems with the 2004 Chevrolet Silverado 2500?
Owners of the 2004 Chevrolet Silverado 2500 report brake problems more than anything else, and most of those complaints center on steel brake lines that rust through and let the pedal fall to the floor. The issues reported most often: Rusted-through brake lines, pedal to the floor; Speedometer and dashboard gauges read wrong or fail; Rough running or loss of power from fuel injectors.
How many NHTSA complaints does the 2004 Chevrolet Silverado 2500 have?
NHTSA recorded 368 consumer complaints for the 2004 Chevrolet Silverado 2500 as of Oct 30, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
What part of the 2004 Chevrolet Silverado 2500 is reported most often?
Brakes is named most often, in 168 complaints (46% of the total), followed by electrical system with 105.
Has the 2004 Chevrolet Silverado 2500 been recalled?
NHTSA lists no recall campaigns for this model year in the data used here. To check a specific vehicle, enter its VIN at nhtsa.gov/recalls.
What gas mileage does the 2004 Chevrolet Silverado 2500 get?
The EPA rates the 2004 Chevrolet Silverado 2500 (Silverado 2500 HD 2WD CNG, 6.0L 8-cyl · natural gas) at 10 mpg combined, 9 city and 11 highway, with an estimated annual fuel cost of $4,600 at 15,000 miles a year. Other engine and drive versions are rated differently.
At what mileage are problems with the 2004 Chevrolet Silverado 2500 reported?
Among the 335 complaints that include a mileage, the median is 73,800 miles and the middle half falls between 50,000 and 104,000 miles; 24% were filed for vehicles with under 50,000 miles.
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 30, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate. Fuel economy is from the EPA and DOE (fueleconomy.gov).
Complaint counts come from NHTSA’s public complaint database; we count each complaint once. The source records for this vehicle are on nhtsa.gov. Scores and trends are our own summaries of that data, described in the methodology. This page is not legal, safety or repair advice: for a specific vehicle, check its VIN at nhtsa.gov/recalls and ask a qualified mechanic. See an error? Tell us.