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2004 Chevrolet Silverado 2500

Owner reports · Recalls · Investigations

More warning signs than most Silverado 2500 years

Owner complaints for the 2004 Chevrolet Silverado 2500 are substantially higher than the model-year median of 81.

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When problems were reported

Mileage at the reported incident

336 reports with mileage · 32 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Electrical System. Review the 105 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes. Review the 99 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes, Hydraulic. Review the 68 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

19 crash reports10 fire reports8 injury reports

Fuel System, Diesel complaints

8 reports
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160,000 miles · Aug 22, 2014
Fuel System, Diesel

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 W…

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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. I FEEL THIS COULD BE A SAFETY CONCERN. FORTUNATELY I WAS ABLE TO GET TO THE SIDE OF THE ROADWAY WITHOUT INCIDENT. I HAVE SENT THREE EMAILS TO [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI #10627442

96,764 miles · Oct 14, 2010
Engine And Engine CoolingFuel System, DieselPower Train

BOUGHT THE TRUCK IN OCTOBER OF 2009, TOOK TO DEALERSHIP ON 12/17/2009 WITH COMPLAINTS MILEAGE OF 96,764 OF LOW ENGINE POWER, HARD TO START TRUCK,,,,GLOW PLUGS WERE BAD CORRODED PARK NEUTRAL SWITCH, CORROSION ON BRAKE LINES..PAID $ 3,600 IN REPAIRS THEN AROUND LATE SEPTEMBER 9-28-2010TRUCK DIED A FOURWAY INTERSECTION...WAS A…

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BOUGHT THE TRUCK IN OCTOBER OF 2009, TOOK TO DEALERSHIP ON 12/17/2009 WITH COMPLAINTS MILEAGE OF 96,764 OF LOW ENGINE POWER, HARD TO START TRUCK,,,,GLOW PLUGS WERE BAD CORRODED PARK NEUTRAL SWITCH, CORROSION ON BRAKE LINES..PAID $ 3,600 IN REPAIRS THEN AROUND LATE SEPTEMBER 9-28-2010TRUCK DIED A FOURWAY INTERSECTION...WAS ALMOST HIT BY A CAR...TOWED TO NEAREST SERVICE FLEET SOURCE...FOUND OUT INJECTORS WERE BAD...WORK WAS STARTED FOR REPAIRS...THEN I FOUND OUT THE GLOW PLUGS...WHICH I PAID FOR ALREADY...AND THE INJECTORS WERE SERVICE BULLETINS...CALLED FLEET TOLD THEM TO STOP REPAIRS...CALLED THE DEALERSHIP...THAT HAD THE TRUCK IN DECEMBER...ASK WHY THEY CHARGED ME FOR THE GLOW PLUGS AND WHY THE DID NOT FIX THE INJECTORS...WHEN IT WAS IN THERE.....DEALERSHIP HUNG UP ON ME...CALLED 1-800-790-5700..SPOKE WITH GM TOLD THEM ABOUT MY CHEVY PROBLEMS...THEY CLAIM THAT MY INJECTORS WOULD NOT BE COVERED...AS IT WAS NOT A DEALERSHIP....FUNNY THING IS THAT FLEET SOURCE IS A CERTIFIED REBUILDER FOR BOSCH, AND SATADYNE BY THE MANUFACTURE FOR THESE PARTS THAT ARE USED IN ALL GM VEHICLES....SO IF YOU TAKE YOUR TRUCK TO A DEALER...THEY GET THEIR PARTS FROM THESE PEOPLE.....GM HAS A HISTORY OF PUTTING ON BULLETINS FOR ITEMS...AND CLAIMING WHEN YOU BRING IN YOUR TRUCK THAT THE PART DOES NOT MEET THE PERIMETER FOR REPLACEMENT....I ABOUT ANOTHER $ 3,200.00 THAT MAKES ABOUT $ 5,0000.00 DOLLARS OF ITEMS THAT PEOPLE HAVE COMPLAINED OUT...HAD RECALLS..SERVICE BULLETINS....NEVER WILL BY ANYTHING THAT GM MAKE AGAIN. *TR

NHTSA ODI #10360425

17,000 miles · Sep 2, 2010
Fuel System, Diesel

2004 CHEVY 2500 HD TRUCK WITH 6.6 DURAMAX DIESEL LOSE FUEL SUCTION. MUST MANUALLY PUMP UP FUEL SYSTEM TO GET TRUCK STARTED. *TR

NHTSA ODI #10353580

Mileage unknown · Jan 27, 2010
Fuel System, Diesel

FUEL INJECTORS GO BAD CAUSING ENGINE TO STALL AND LURCH FORWARD WHILE IDLING. THE TRUCK HAS BEEN TO THE DEALER AND HAD THIS PROBLEM REPAIRED 3 TIMES AND IS DOING IT AGAIN *CN *TR

NHTSA ODI #10302894

102,000 miles · Oct 27, 2009
Fuel System, DieselFire

TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500 HD. WHILE DRIVING HE SAW SMOKE COMING FROM THE TAIL PIPE, AND THEN HE SMELLED A BURNING ODOR. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION. THE TECHNICIAN CONCLUDED THAT THE THERMOSTATS ARE NOT ALLOWING THE VEHICLE TO ACHIEVE OPERATING TEMPERATURE AND INJECTORS 5, 6, 1 …

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TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500 HD. WHILE DRIVING HE SAW SMOKE COMING FROM THE TAIL PIPE, AND THEN HE SMELLED A BURNING ODOR. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION. THE TECHNICIAN CONCLUDED THAT THE THERMOSTATS ARE NOT ALLOWING THE VEHICLE TO ACHIEVE OPERATING TEMPERATURE AND INJECTORS 5, 6, 1 ARE DEFECTIVE. THE REPAIR WILL BE PERFORMED AT THE OWNERS EXPENSE. THE FAILURE MILEAGE WAS 102000. THE CURRENT MILEAGE WAS 103000.

NHTSA ODI #10289961

59,000 miles · Jan 29, 2009
Fuel System, Diesel

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. *TR

NHTSA ODI #10256687

65,000 miles · Jun 12, 2008
Fuel System, Diesel

TL*THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500 4X4 DIESEL. WHILE DRIVING VARIOUS SPEEDS, THE VEHICLE WOULD MISFIRE. THE NEXT MISFIRE WOULD RECUR 45 MINUTES LATER, AND THE THIRD MISFIRE WOULD NORMALLY RECUR AN HOUR AFTERWARDS. THE FAILURE WAS INTERMITTENT. THE CONTACT COULD NOT DRIVE OVER 25 MPH AND THE VEHICLE CONSTANTL…

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TL*THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500 4X4 DIESEL. WHILE DRIVING VARIOUS SPEEDS, THE VEHICLE WOULD MISFIRE. THE NEXT MISFIRE WOULD RECUR 45 MINUTES LATER, AND THE THIRD MISFIRE WOULD NORMALLY RECUR AN HOUR AFTERWARDS. THE FAILURE WAS INTERMITTENT. THE CONTACT COULD NOT DRIVE OVER 25 MPH AND THE VEHICLE CONSTANTLY JERKED. IN JANUARY OF 2008, SHE TOOK HER VEHICLE TO THE DEALER AND THEY REPLACED TWO FUEL INJECTORS. ON APRIL 2, 2008, THE DEALER REPLACED 8 FUEL INJECTORS. AFTER THE MOST RECENT FAILURE, THE CONTACT TOOK THE VEHICLE TO THE DEALER FOR A DIAGNOSTIC. THEY COULD NOT LOCATE ANY FAILURES. THE FAILURE MILEAGE WAS 65,000 AND CURRENT MILEAGE WAS 97,000.

NHTSA ODI #10230855

95,000 miles · Oct 1, 2007
Engine And Engine CoolingFuel System, Diesel

TL*THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500 HD. WHILE DRIVING UPHILL AT 55 MPH, THE ENGINE FAILED WITHOUT WARNING. THE CONTACT WAS ABLE TO COAST TO THE SIDE OF THE ROAD. HE REPRIMED THE FUEL FILTER AND THE VEHICLE DROVE APPROXIMATELY A MILE AND A HALF BEFORE IT SHUT OFF AGAIN. HE HAD TO REPRIME THE FILTER AGAIN. THE…

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TL*THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500 HD. WHILE DRIVING UPHILL AT 55 MPH, THE ENGINE FAILED WITHOUT WARNING. THE CONTACT WAS ABLE TO COAST TO THE SIDE OF THE ROAD. HE REPRIMED THE FUEL FILTER AND THE VEHICLE DROVE APPROXIMATELY A MILE AND A HALF BEFORE IT SHUT OFF AGAIN. HE HAD TO REPRIME THE FILTER AGAIN. THE CONTACT PULLED OVER TO ALLOW THE VEHICLE TO COOL OFF. THE VEHICLE WAS TAKEN TO A SERVICE STATION AND THE MECHANIC SPOKE WITH CHEVROLET, WHO WAS NOT AWARE OF ANY RECALLS. THE CURRENT AND FAILURE MILEAGES WERE 95,000. *UPDATED 12/27/07 *LJ UPDATED 12/12/07 *TR

NHTSA ODI #10204551

Official recalls

0

No recalls in this snapshot.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

0

No exact-year investigations in this snapshot.