2004 GMC Sierra 3500 Fuel system Problems
- Complaints
- 4about this part
- Share
- 17%of 24 total for the year
- Median mileage
- 121,000miles
- Trend
- Not enough dataFewer than 15 complaints, too few for a reliable trend.
NHTSA recorded 4 complaints about the fuel system of the 2004 GMC Sierra 3500, 17% of the 24 complaints for this model year. Where a mileage was given, the median is 121,000 miles. 1 a fire, according to the filers.
Fewer than 15 complaints name this part, so treat the figures as a rough indication only.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“- the contact states that sometime in august of 2006, fuel injected number 8 failed in her vehicle. On december 4th the electrical system failed to work involving injected number 8. On december 11th, injected number six on contact diesel engine truck failed while driving 55 MPH. The contact states that he has spent over $1,000 of dollars repairing his truck and would like to know, if the manufacturer has confirm that there is a problem with the fuel injectors. The vehicle has been in for repair several of times, contact can provide any repair invoices if needed”
NHTSA complaint #10176560, filed 2006-12, 125,000 miles“The 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.”
NHTSA complaint #10278985, filed 2009-07, 30,000 miles“The contact owns a 2004 Gmc SIERRA 3500. While driving approximately 40 MPH, the vehicle became resistant to acceleration. The vehicle was then towed to the dealer where the technicians stated that all eight fuel injectors would need to be replaced. The vehicle was repaired. After the repairs were made, the failure recurred. The contact stated the previous owner of the vehicle experienced the same failure and had the fuel injectors replaced. The vehicle was then traded for another vehicle. The vehicle was not repaired. The approximate failure mileage was 149,411.”
NHTSA complaint #10396956, filed 2011-04, 149,411 miles“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. …”
NHTSA complaint #10441733, filed 2011-12, 117,000 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…
- 10209734Mar 22, 2022This service bulletin provides information for maintenance cleaning of the fuel injectors and gasoline detergent additive.
- 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…
- 10126346Oct 2, 2015This informational bulletin provides information to dealership personnel on identifying Duramax Diesel overpower engine breakdown or non-function due to aftermarket power-up…
- 10250012Jul 1, 2014Duramax® Diesel Glow Plugs Difficult to Install Due to Carbon Buildup - New Glow Plug Bore Reamer Available
- 10246499Jul 1, 2014Duramax® Diesel Glow Plugs Difficult to Install Due to Carbon Buildup - New Glow Plug Bore Reamer Available
Fuel system: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2026 | 1 | 20% |
| 2024 | 5 | 10% |
| 2023 | 2 | 7% |
| 2022 | 1 | 3% |
| 2021 | 2 | 10% |
| 2020 | 6 | 12% |
| 2019 | 1 | 8% |
| 2018 | 1 | 7% |
| 2016 | 3 | 16% |
| 2015 | 2 | 6% |
| 2014 | 2 | 29% |
| 2013 | 2 | 14% |
| 2012 | 3 | 33% |
| 2011 | 2 | 10% |
| 2008 | 3 | 12% |
| 2005 | 1 | 4% |
| 2004 | 4 | 17% |
| 2003 | 1 | 14% |
| 2002 | 6 | 30% |
| 2001 | 8 | 22% |
| 1999 | 1 | 5% |
| 1998 | 2 | 17% |
Other parts of the 2004 GMC Sierra 3500
14 complaintsElectrical system
5 complaintsSteering
2 complaintsBody and structure
1 complaintsTires
1 complaintsTransmission and drivetrain
1 complaints
← All problems reported for the 2004 GMC Sierra 3500
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