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GMC CanyonModel year report

2004 GMC Canyon Problems

Complaints
80filed with NHTSA
Median mileage
74,456miles, 57 complaints with mileage
Recalls
3campaigns on record
Trend
StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
NHTSA crash rating
—overall rating starts with 2011 models
EPA fuel economy
18 mpgcombined, 2.8L 4-cyl RWD · 16 city / 23 hwy

Sources: NHTSA records for the 2004 GMC Canyon (complaints, recalls, investigations), NHTSA crash tests, EPA fuel economy. Report an error

What owners report

Owners of this model year most often describe rear frame and undercarriage corrosion, frequently found during routine service at independent shops or dealers, sometimes with the truck reported as not driveable afterward. A second cluster of complaints covers intermittent no-start conditions tied to the anti-theft Passlock system, along with brake lamps that stop working and take cruise control with them. Most reports in the sample arrive between roughly 50,000 and 130,000 miles.

  1. Body and structure

    Rear frame and undercarriage rust

    • 14 complaints (18%)
    • median 113,115 mi at 14.4 yrs old (12 state mileage)
    • filed 2016–2024

    Owners describe frames, rear subframes, leaf-spring mounts and lower control arm mounts rusting through or breaking, often discovered during unrelated repairs. Several say the shop told them the truck was not safe to drive, and that dealers acknowledged hearing about similar rust but said no recall covered the repair. A few describe holes in the boxed frame or a frame bent after a bump or train tracks. Mileage in the sample ranges widely, from about 53,000 to 280,000, and many reports come from northern or road-salt states.

    1 related service bulletin

    What to check: Have the frame inspected from below, especially the rear section ahead of the rear tires and the leaf-spring and control-arm mounting points, looking for flaking rust, holes or cracks. Ask whether the truck has spent winters in a salt-belt state.

    2 excerpts from owner complaints in NHTSA records

    “Truck frame has totally rusted out with only 80,000 miles on the truck. Body shows nothing, but the frame is disintegrating. I recently purchased this based on pictures which showed an extremely clean body and interior (true). Got it delivered to my mechanic who called me to show me the holes in the frame!”

    NHTSA complaint #11030214, filed 2017-09, 78,000 miles

    “The frame has totally rusted and is breaking apart while the rest of the truck is in very good condition. See photos. This was noticed on 09-18-17. I bought this truck new in 2004 and as you can tell by the mileage it has been driven very little. Please contact me with any questions.”

    NHTSA complaint #11030190, filed 2017-09, 53,600 miles
  2. Electrical system

    Passlock anti-theft prevents starting

    • 11 complaints (14%)
    • median 62,146 mi at 6.9 yrs old (10 state mileage)
    • 1 mention a crash, fire or injury
    • filed 2005–2019

    Owners describe the engine refusing to crank or start intermittently, with the Passlock or security light staying on, then starting normally after waiting around ten minutes. Some replaced fuel pumps before learning the cause, and complaints describe dealers charging diagnostic fees without a lasting remedy. Mostly reported between about 50,000 and 130,000 miles, with no clear seasonal pattern in the sample.

    2 related service bulletins

    What to check: Ask whether the ignition switch or Passlock-related components have been replaced, and check that the truck starts readily from cold and after short stops on the test drive.

    2 excerpts from owner complaints in NHTSA records

    “The Gmc passlock lockout feature is a pain in the rear of nearly every car/truck owner having this feature. Today, for the umpteenth time, my vehicle would not start when I tried to start it up after fueling. My truck was stuck at the gas pumps, obstructing other patrons waiting to gas up. I sat waiting for about 5 minutes and tried starting it again, while getting dirty looks from other people waiting to gas up. Of, course it didn't start because I hadn't waited the requisite 10 minutes. …”

    NHTSA complaint #11156872, filed 2018-12, 68,762 miles

    “2004 Gmc Canyon, 113,000 miles. About a year ago started having starting problems. Changed fuel pump, out of my pocket, truck out of warranty. $400 later truck still had starting problems. Noticed when it won't start passlock light is on. Have to wait 10 minutes or so then it'll start. Happening more frequent now. Dealer wants $90 to diagnose plus cost of parts & labor. I've noticed quite a few other Canyon owners having same problem. How many vehicles will this have to effect before recall is done? …”

    NHTSA complaint #10359507, filed 2010-10, 96,000 miles
  3. Exterior lighting

    Brake lights stop working, cruise control quits

    • 8 complaints (10%)
    • median 73,000 mi at 3.0 yrs old (7 state mileage, few)
    • filed 2006–2013

    Owners report rear brake lamps that fail entirely or stay lit, sometimes along with the center high-mounted stop lamp, and cruise control that stops engaging. Several had the brake light switch replaced repeatedly, and some say their vehicle was not covered by the brake-lamp-switch recalls even after a dealer confirmed the same symptom. Reported across the sample from very low mileage up to about 160,000 miles, often as an intermittent failure.

    Recall 06V139000Recall 09V3100002 related service bulletins

    What to check: With a helper, confirm all rear brake lamps and the high-mounted lamp come on with the pedal and go off when released; check that cruise control engages. Ask whether the brake light switch has been replaced and whether the truck was included in brake-lamp recalls.

    2 excerpts from owner complaints in NHTSA records

    “Cruise control failed in june 2006. Rear brake lights failed in september 2006. Found NHTSA id 06v139000 and showed to dealer service. However, they and Gmc indicate that there was no recall on my VIN. Had to pay $149.36 to repair and missed work because it took all day to get part and install. Gmc would not reimburse until it a recall for my VIN is announced.”

    NHTSA complaint #10169727, filed 2006-10, 44,856 miles

    “I have a 2004 Gmc Canyon and was pulled over and told that my brake lights were not working. When I looked up how to fix this problem or possible causes ( the bulbs were fine ) I noticed that there were a lot of hits for a recall for this exact problem on the exact make and model. The turn signals and night time lights all work fine, but no luck with any of the brake lights.”

    NHTSA complaint #10358014, filed 2010-09, 110,530 miles

Buying note. A pre-purchase inspection from below is the most useful step on this model year, since frame corrosion is the most frequent theme in owner reports and is not covered by a recall. Also verify brake lamps, cruise control, starting behavior and blower operation on the test drive, and ask for records of any related repairs.

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 80 consumer complaints for the 2004 GMC Canyon. 57 of the complaints include a mileage, and 32% of those were filed for vehicles with under 50,000 miles; the median is 74,456 miles. Of all complaints, 3 involved a crash, 4 a fire, 1 an injury, according to the filers. NHTSA lists 3 recall campaigns and 486 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.

Also reported: Transmission and drivetrain (4), Wheels (4), Fuel system (3), Equipment (2), Seats (2), Visibility (wipers, defrost, mirrors) (2), Seat belts (1), Vehicle speed control (1).

Example complaints

Body and structure: “On october 5, 2016, I took my truck over to my mechanic to have my brake lines bled as I replaced the right front caliper. When they took the right front tire off, they had shown me that the lower left control arm mount was going to fail. There was no failure as of yet and the vehicle was stationary when the problem was found. It was severely rusted out and cracked, as well as the frame and area around it was severely rusted and holes were visible. …”

NHTSA complaint #10914806, filed 2016-10, 122,700 miles

Electrical system: “After reading a post from the 116 affected Gmc Canyon owners I have the exact same problem. Last month june 2019 while driving home from work my AC just quit working (hot weather in sacramento), no matter what speed it was on 1 through 4. I also smelt a burning smell. Today while driving my truck to the realer to get it analyzed I hit a bump and the blower started working again on speed 4. Bob from john l sullivan chevy just called to confirm the diagnosis...the connector that connects to the blower was melted and the resister was burnt.”

NHTSA complaint #11231695, filed 2019-07, 183,000 miles

Suspension: “My 2004 Gmc Canyon was found to have both front tires completly worn out along the inside edge at 10000 miles, Gmc has several sevice bulletins about this problem but say they don't know what caused the tire wear and will not cover it under the warrenty”

NHTSA complaint #10129492, filed 2005-07, 10,000 miles

Engine cooling: “There is a high pitched whining coming from the engine whenever I use the air conditioning. The whine is not constant. It sounds like it makes the noise when the air conditioning compressor kicks in. I bought this vehicle on 4/29/2004.”

NHTSA complaint #10074872, filed 2004-06, 75 miles

Mileage when problems were reported

32% of the 57 complaints with a mileage were filed for vehicles with under 50,000 miles; the middle half falls between 41,051 and 106,500 miles.

11%0–109%10–2512%25–5019%50–7521%75–10018%100–15011%150+
Share of complaints by mileage when the problem was reported, in thousands of miles (57 complaints with mileage). Red bars: under 50,000 miles. Bucket widths differ. Median: 74,456 miles.

Complaints by year filed

Trend: stable. Complaints filed in the last 3 full calendar years are within 25% of the 3 years before.

’0511’08’11’14’17’20’24
Complaints by year the complaint was filed with NHTSA. Red bars: the last 3 full calendar years used for the trend. The current year (2026) is partial.

Crash test ratings

NHTSA's 5-Star Safety Ratings for the 2004 GMC Canyon. Frontal results are shown driver / passenger; rollover shows the star rating and NHTSA's estimated risk of rolling over in a single-vehicle crash.

VersionOverallFrontalSideSide poleRollover
Canyon · sedan not rated4 / 4———

Ratings before the 2011 model year come from an older, less demanding test and are not comparable with ratings for 2011 and later.

Source: NHTSA New Car Assessment Program (5-Star Safety Ratings), nhtsa.gov/ratings.

Fuel economy and running cost

EPA ratings for each 2004 GMC Canyon version. Annual fuel cost is the EPA's estimate at its current fuel prices for 15,000 miles a year (55% city driving).

VersionEngineTransmissionCityHwyComb.Fuel / yr
Canyon 2WD2.8L 4-cyl5-speed manual182421$3,200
Canyon 2WD2.8L 4-cyl4-speed automatic162318$3,700
Canyon 2WD3.5L 5-cyl5-speed manual172319$3,550
Canyon 2WD3.5L 5-cyl4-speed automatic162218$3,700
Canyon 4WD2.8L 4-cyl5-speed manual172219$3,550
Canyon 4WD2.8L 4-cyl4-speed automatic162118$3,700
Canyon 4WD3.5L 5-cyl4-speed automatic162118$3,700
Canyon 4WD3.5L 5-cyl5-speed manual162118$3,700
Canyon Crew Cab 2WD2.8L 4-cyl5-speed manual182420$3,350
Canyon Crew Cab 2WD2.8L 4-cyl4-speed automatic162318$3,700
Canyon Crew Cab 2WD3.5L 5-cyl4-speed automatic162218$3,700
Canyon Crew Cab 4WD2.8L 4-cyl5-speed manual172219$3,550
Canyon Crew Cab 4WD2.8L 4-cyl4-speed automatic162118$3,700
Canyon Crew Cab 4WD3.5L 5-cyl4-speed automatic152117$3,950

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

Recall details for the 2004 GMC Canyon → · Check a 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. 486 on record; the latest 10 are shown.

See all 486 bulletins →

Other model years of the GMC Canyon

YearComplaintsMedian miRecallsCrash ★MPGScore (50 = typical)Trend
202683502420—Too new
2025813,5002420—Too new
20242074,0003420Too new to compareToo new
2023623,000342099 · MoreToo new
20222822,212142240 · TypicalRising
20211246,5002422—Not enough data
20201418,5000422—Not enough data
20191736,0820422—Rising
20185322,000142243 · TypicalStable
20176627,803142256 · TypicalFalling
201627146,5234422100 · MoreStable
201530354,6808422100 · MoreFalling
20122345,0002—21—Stable
20111251,0735—21—Not enough data
2010810,0002—21—Not enough data
20092749,9283—2030 · FewerFalling
20083868,0002—200 · FewerStable
20074273,6513—18Not compared (before 2008)Falling
20064860,0004—19Not compared (before 2008)Falling
200511350,1063—18Not compared (before 2008)Falling
20048074,4563—18Not compared (before 2008)Stable

All GMC Canyon model years · Best and worst years by complaints

Frequently asked questions

What are the most common problems with the 2004 GMC Canyon?

Owners of this model year most often describe rear frame and undercarriage corrosion, frequently found during routine service at independent shops or dealers, sometimes with the truck reported as not driveable afterward. The issues reported most often: Rear frame and undercarriage rust; Passlock anti-theft prevents starting; Brake lights stop working, cruise control quits.

How many NHTSA complaints does the 2004 GMC Canyon have?

NHTSA recorded 80 consumer complaints for the 2004 GMC Canyon as of Oct 28, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.

What part of the 2004 GMC Canyon is reported most often?

Body and structure is named most often, in 16 complaints (20% of the total), followed by electrical system with 13.

Has the 2004 GMC Canyon been recalled?

NHTSA lists 3 recall campaigns for this model year. To check a specific vehicle, enter its VIN at nhtsa.gov/recalls.

What gas mileage does the 2004 GMC Canyon get?

The EPA rates the 2004 GMC Canyon (Canyon 2WD, 2.8L 4-cyl) at 18 mpg combined, 16 city and 23 highway, with an estimated annual fuel cost of $3,700 at 15,000 miles a year. Other engine and drive versions are rated differently.

At what mileage are problems with the 2004 GMC Canyon reported?

Among the 57 complaints that include a mileage, the median is 74,456 miles and the middle half falls between 41,051 and 106,500 miles; 32% were filed for vehicles with under 50,000 miles.

About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 28, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate. Crash ratings are from NHTSA’s New Car Assessment Program. 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.