2004 Chevrolet Silverado 2500 Fuel system Problems
- Complaints
- 26about this part
- Share
- 7%of 368 total for the year
- Median mileage
- 65,636miles
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
NHTSA recorded 26 complaints about the fuel system of the 2004 Chevrolet Silverado 2500, 7% of the 368 complaints for this model year. Where a mileage was given, the median is 65,636 miles. 1 a fire, according to the filers.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“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 miles“My 2004 Chevrolet SILVERADO 2500 hd has had multiple brake issues. The brake lines and fuel line have rusted out. Approximately 2 years ago I had break line rust out and they where replaced. They have rusted out again.my truck is very well cared for and is clean and not driven often. I have had multiply conversations with general motors hotline and have not got anywhere. I have researched the web and see this is a big problem with general motors products.my truck now has about 70,000 miles and is still very clean and very well kept. …”
NHTSA complaint #10679639, filed 2015-01, 56,000 miles“Fuel gauge at fill up went past full and completely clock wise...gauge reading is all over the place everytime I start engine. Vehicle has 59,000 miles. I have to read my range reading, (uncertain of accuracy)to approximate fuel in diesel tank.”
NHTSA complaint #10256687, filed 2009-01, 59,000 miles“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. This immediately shut down the affected cylinder bank resulting in an immediate reduction of engine power. …”
NHTSA complaint #10627442, filed 2014-08, 160,000 miles“I had my fuel injectors replaced in june of 2010 under an extended warranty from GM with no out of pocket cost. 18 months later I am having the same problem, fuel injector failure as diagnosed by a local Chevrolet dealer, but being told that I am now out of warranty and it will cost $3500+ to repair. If there is a defect in the injectors, previously covered for 7 years/200,000 miles, why are the new improved injectors only coming with 12 months/12,000 miles. Gm has a fuel injector problem with their duramax diesels that need to be addressed. …”
NHTSA complaint #10439655, filed 2011-12, 102,589 milesRelated service bulletins
- 11004761Jun 28, 2024This 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…
- 10209741Mar 22, 2022This service bulletin provides the technician with additional information on fuels, fuel additives and fuel management.
- 10199281May 25, 2021This service bulletin provides diagnostic tips/steps on testing for possible EVAP leaks in the system to correct a customer concern of an MIL Illuminated with DTCs P0442 and/or…
- 10190437Mar 30, 2021This Preliminary Information communication provides information to the technician about engine block of possible cylinder bore damage, scoring or out of round as the possible…
- 10176607May 8, 2020This technical 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…
- 10176310May 8, 2020This Preliminary information communicates the use of Winter grade fuel during the warm months of 2020 and the potential rivability issues that it can cause. The ongoing…
- 10172887Feb 11, 2020This SKU is a Diesel Fuel Filter Housing. The customer communication requested return of unsold inventory to inspect the fuel filter threads. The threads may be misformed such…
- 10171878Jan 2, 2020This informational 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…
- 10157018Sep 20, 2017This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester…
- 10137635May 10, 2017This informational bulletin advises of a new fuel injection kit used for decarbonizing the intake valves, and explains how toptier fuels should be used to reduce carbon build up.
Fuel system: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2026 | 1 | 8% |
| 2025 | 2 | 6% |
| 2024 | 9 | 6% |
| 2023 | 2 | 4% |
| 2022 | 2 | 2% |
| 2021 | 9 | 10% |
| 2020 | 11 | 10% |
| 2019 | 11 | 15% |
| 2018 | 9 | 17% |
| 2017 | 3 | 6% |
| 2016 | 13 | 11% |
| 2015 | 19 | 11% |
| 2014 | 8 | 20% |
| 2013 | 10 | 20% |
| 2012 | 10 | 19% |
| 2011 | 12 | 12% |
| 2010 | 2 | 10% |
| 2009 | 1 | 2% |
| 2008 | 7 | 4% |
| 2007 | 10 | 5% |
| 2006 | 6 | 3% |
| 2005 | 24 | 9% |
| 2004 | 26 | 7% |
| 2003 | 29 | 6% |
| 2002 | 30 | 9% |
| 2001 | 23 | 6% |
| 2000 | 7 | 5% |
| 1999 | 8 | 10% |
| 1998 | 8 | 11% |
| 1997 | 6 | 9% |
Other parts of the 2004 Chevrolet Silverado 2500
168 complaintsElectrical system
105 complaintsEngine cooling
23 complaintsSteering
16 complaintsTransmission and drivetrain
15 complaintsEngine
14 complaintsSuspension
12 complaintsWheels
9 complaintsVehicle speed control
6 complaintsOther or unknown
5 complaintsTires
5 complaintsAir bags
4 complaints
← All problems reported for the 2004 Chevrolet Silverado 2500
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 31, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology