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2004 GMC Sierra 2500

Owner reports · Recalls · Investigations

More warning signs than most Sierra 2500 years

Owner complaints for the 2004 GMC Sierra 2500 are substantially higher than the model-year median of 46.

About this comparison →

When problems were reported

Mileage at the reported incident

122 reports with mileage · 21 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 48 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes. Review the 33 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes, Hydraulic. Review the 22 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

4 crash reports4 fire reports3 injury reports

What owners actually said

143 reports
40,750 miles · Aug 22, 2011
Service Brakes, Hydraulic

THIS COMPLAINT COVERS MY 2004 GMC SIERRA 2500HD CREW CAB 4WD. ALMOST ONE YEAR AGO I HAD A MAIN BRAKE LINE BLOW UNDERNEATH THE DRIVERS SIDE OF THE TRUCK. THE LINE WAS SO CORRODED IT WAS NO WONDER. THIS INCIDENT HAPPENED ON 9-7-10. I WAS HOOKED TO MY FIFTH WHEEL CAMPER AND WAS PREPARING TO PULL OUT OF DRIVEWAY AND WHEN I PLACE…

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THIS COMPLAINT COVERS MY 2004 GMC SIERRA 2500HD CREW CAB 4WD. ALMOST ONE YEAR AGO I HAD A MAIN BRAKE LINE BLOW UNDERNEATH THE DRIVERS SIDE OF THE TRUCK. THE LINE WAS SO CORRODED IT WAS NO WONDER. THIS INCIDENT HAPPENED ON 9-7-10. I WAS HOOKED TO MY FIFTH WHEEL CAMPER AND WAS PREPARING TO PULL OUT OF DRIVEWAY AND WHEN I PLACED FOOT ON BRAKE TO SHIFT INTO DRIVE IT BLEW. THANKFULLY I WAS JUST BEGINNING TO MOVE. I HAD THE TRUCK TOWED TO MY LOCAL MECHANIC AND HE REPLACED THE LINE AND FLUSHED SYSTEM. NOW AGAIN ON 8-22-11 SAME SITUATION OCCURRED. THE LINE BLEW IN EXACTLY THE SAME POSITION AS FIRST TIME ONLY A DIFFERENT LINE THIS TIME. NOT TO MENTION THE OTHER CORROSION ON THE BRAKE CALIPERS AND HARDWARE THAT RENDERED MY REAR BRAKES USELESS. HAD TO REPLACE ROTORS AND PADS DUE TO STICKING BRAKE PAD WEARING TO POINT OF METAL TO METAL CONTACT. DID I MENTION I PURCHASED THIS TRUCK NEW AND IT NOW HAS ONLY 38,500 MILES. RARELY DOES IT GET DRIVEN IN SNOW AND SALT. I HAVE ALL RECEIPTS FOR PARTS THAT THIS PROBLEM HAS CAUSED ME. IM JUST THANKFUL THAT I WASN'T TOWING AS I USUALLY DO WHEN IM DRIVING THIS TRUCK. I'VE TALKED TO MY LOCAL DEALERSHIP DON HALL IN ASHLAND, KY AND THEY CITE HUNDREDS OF TRUCKS HAVING THIS SAME PROBLEM. WHEN ARE THEY GOING TO DO SOMETHING ABOUT THIS. I AM A LOYAL GM FAN BUT I WORKED AT A TOYOTA DEALERSHIP FOR TWO YEARS SELLING USED VEHICLES. I MADE IT A HABIT OF CHECKING ALL OF OUR GM TRUCK TRADE-INS FOR THIS RUST PROBLEM AND THEY TOO HAD THIS. I SAW EVEN TWO TO THREE YEAR OLD VEHICLES RUSTED TO THE POINT OF COLLAPSE. ONE OF THESE BEING A $65000 CADILLAC ESCALADE. APPALLING. *TR

NHTSA ODI #10421078

42,000 miles · Aug 22, 2011
Service Brakes, Hydraulic

TL* THE CONTACT OWNS A 2004 GMC SIERRA 2500 HD. THE CONTACT WAS DRIVING 25 MPH AND APPLIED THE BRAKES FOR A TRAFFIC STOP WHEN THERE WAS A PULSATION COMING FROM THE BRAKES. THIS CAUSED THE BRAKES TO BE DEPRESSED ABNORMALLY INTO THE FLOORBOARD. THE CONTACT COULD NOT STOP THE VEHICLE UNTIL HE ENGAGED THE EMERGENCY BRAKES. THE VEHIC…

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TL* THE CONTACT OWNS A 2004 GMC SIERRA 2500 HD. THE CONTACT WAS DRIVING 25 MPH AND APPLIED THE BRAKES FOR A TRAFFIC STOP WHEN THERE WAS A PULSATION COMING FROM THE BRAKES. THIS CAUSED THE BRAKES TO BE DEPRESSED ABNORMALLY INTO THE FLOORBOARD. THE CONTACT COULD NOT STOP THE VEHICLE UNTIL HE ENGAGED THE EMERGENCY BRAKES. THE VEHICLE WAS DRIVEN TO THE DEALER AND AFTER INSPECTION, THE DEALER INFORMED HIM THAT THE BRAKE LINE WAS RUSTED AND HAD RUPTURED. IN ADDITION, THE DEALER ADVISED THAT THERE WERE NO RECALLS FOR THE FAILURE. THE MANUFACTURER WAS CONTACTED WHO ADVISED THAT A REPRESENTATIVE WOULD LATER RETURN HIS CALL. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 42,000. UPDATED 09/28/2011 *LN *TR

NHTSA ODI #10420915

72,600 miles · Aug 17, 2011
Electrical System

DRIVING DOWN/UP A VERY CURVY ROAD AND MY SPEEDOMETER BECAME INACCURATE. I HAD TO USE MY GPS THE BEST I COULD TO KNOW HOW FAST I WAS GOING, SO THAT I WOULDN'T SPEED. THE SPEEDOMETER WOULD MOVE UP AND DOWN BUT AT THE WRONG SPEEDS. IN PARK AT ONE POINT SAID 56MPH, AT ANOTHER POINT 45-50MPH. I TOOK IT TO MY LOCAL CHEVY/GMC DEALER TO…

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DRIVING DOWN/UP A VERY CURVY ROAD AND MY SPEEDOMETER BECAME INACCURATE. I HAD TO USE MY GPS THE BEST I COULD TO KNOW HOW FAST I WAS GOING, SO THAT I WOULDN'T SPEED. THE SPEEDOMETER WOULD MOVE UP AND DOWN BUT AT THE WRONG SPEEDS. IN PARK AT ONE POINT SAID 56MPH, AT ANOTHER POINT 45-50MPH. I TOOK IT TO MY LOCAL CHEVY/GMC DEALER TO GET IT REPAIRED. WAITING FOR THE APPROPRIATE PARTS, BUT THE PARTS ARE GOING TO COST ME OVER $400 + LABOR. THIS IS A DANGEROUS PROBLEM TO HAVE, ESPECIALLY WHERE IT AFFECTS ALL MY GAUGES, NOT JUST MY SPEEDOMETER, MINE JUST SHOWED ITSELF THROUGH THE SPEEDOMETER. THIS IS A RIDICULOUS COST TO INCUR FOR SOMETHING THAT SHOULDN'T FAIL IN THE FIRST PLACE. *KB

NHTSA ODI #10419762

Mileage unknown · Aug 16, 2011
Electrical System

RECEIVED A CONDITIONAL LETTER FROM GM STATING THAT MY VEHICLE MY EXPERIENCE A CONDITION RESULTING FROM CORROSION THAT MAY EFFECT THE RELAY RESISTOR MODULE AND WIRE CONNECTOR FOR THE HEATER/HVAC FAN MOTOR. THE LETTER STATES THAT THE WIRE AND/OR RESISTOR COULD OVERHEAT. THIS MAY BE ACCOMPANIED BY A BURNING SMELL OR SMOKE. I HAVE F…

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RECEIVED A CONDITIONAL LETTER FROM GM STATING THAT MY VEHICLE MY EXPERIENCE A CONDITION RESULTING FROM CORROSION THAT MAY EFFECT THE RELAY RESISTOR MODULE AND WIRE CONNECTOR FOR THE HEATER/HVAC FAN MOTOR. THE LETTER STATES THAT THE WIRE AND/OR RESISTOR COULD OVERHEAT. THIS MAY BE ACCOMPANIED BY A BURNING SMELL OR SMOKE. I HAVE FIRST HAND KNOWLEDGE THAT A CO-WORKERS TRUCK CAUGHT FIRE ON JULY 26, 2011 DO TO THIS SPECIFIC PROBLEM. SEVERAL PEOPLE HAVE COMPLAINED VIA THE INTERNET ABOUT FIRE DAMAGE FROM THIS CONDITION. I HAVE TALKED TO GENERAL MOTORS ABOUT THIS ISSUE AND THEY FAILED TO REACT. MY CO-WORKER DID NOT HAVE ANY SYMPTOMS PRIOR TO HIS VEHICLE CATCHING FIRE UNDER HIS DASH THAT TOTALED HIS TRUCK. I AM CONCERNED THAT MY TRUCK WILL CATCH FIRE WITHOUT NOTICE AND AS A RESULT POTENTIALLY BURN DOWN MY HOUSE. WHENEVER SOMEONE DESCRIBES A SYMPTOM AS A BURNING SMELL OR SMOKE IT IS POTENTIALLY TO LATE TO FIX THE ISSUE AND COULD CAUSE BODILY HARM OR DEATH. *KB

NHTSA ODI #10419684

90,500 miles · Aug 14, 2011
Service Brakes, Hydraulic

I OWN A 2004 GMC SIERRA 2500HD 4WD TRUCK. IT HAS 90,500 MILES ON IT. MULTIPLE BRAKE LINES UNDER THE DRIVER SIDE DOOR HAVE RUSTED AND ARE LEAKING BRAKE FLUID. THE VEHICLE IS UNSAFE TO DRIVE AT THIS POINT UNLESS REPAIRS ARE MADE COSTING ME OVER $1000. I CANNOT DRIVE THE TRUCK UNTIL REPAIRS ARE MADE. IT APPEARS AFTER DOING SOM…

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I OWN A 2004 GMC SIERRA 2500HD 4WD TRUCK. IT HAS 90,500 MILES ON IT. MULTIPLE BRAKE LINES UNDER THE DRIVER SIDE DOOR HAVE RUSTED AND ARE LEAKING BRAKE FLUID. THE VEHICLE IS UNSAFE TO DRIVE AT THIS POINT UNLESS REPAIRS ARE MADE COSTING ME OVER $1000. I CANNOT DRIVE THE TRUCK UNTIL REPAIRS ARE MADE. IT APPEARS AFTER DOING SOME ONLINE RESEARCH THAT THERE IS ALREADY A NHTSA INVESTIGATION CONCERNING PREMATURE BRAKE LINE RUSTING/FAILURE ON GM TRUCKS. I HAVE DRIVEN CARS THAT ARE OVER 30 YEARS OLD AND THEY DO NOT HAVE THE KIND OF RUST I HAVE ON MY GMC SIERRA THAT IS ONLY 7 YEARS OLD!!! PLEASE MAKE GM DO A RECALL ON THIS DESIGN FAILURE. THEY ARE ENDANGERING THE LIVES OF THEIR CUSTOMERS! *TR

NHTSA ODI #10419339

69,000 miles · Jul 26, 2011
Electrical System

THE SPEEDOMETER UNEXPECTEDLY STOPPED WORKING ON MY 2004 GMC SIERRA 2500 HD AS I WAS DRIVING DOWN I-4. IT WAS REGISTERING 65MPH ONE MINUTE, THEN THE NEXT 0 MPH. THIS ORIGINALLY HAPPENED APPROXIMATELY 1 1/2 YEARS AGO. I CONTACTED MY DEALER WHERE I PURCHASED THE VEHICLE. T THAT TIME, I HAD APPROXIMATELY 69000 MILES ON THE VEHI…

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THE SPEEDOMETER UNEXPECTEDLY STOPPED WORKING ON MY 2004 GMC SIERRA 2500 HD AS I WAS DRIVING DOWN I-4. IT WAS REGISTERING 65MPH ONE MINUTE, THEN THE NEXT 0 MPH. THIS ORIGINALLY HAPPENED APPROXIMATELY 1 1/2 YEARS AGO. I CONTACTED MY DEALER WHERE I PURCHASED THE VEHICLE. T THAT TIME, I HAD APPROXIMATELY 69000 MILES ON THE VEHICLE. HE TOLD ME TO TRY AND RESTARTING IT AND IT SHOULD START WORKING RIGHT AGAIN. WHICH IT DID. IT HAS CONTINUED TO ACT UP SINCE AND IS BECOMING MORE FREQUENT. THE DEALER NOW TELLS ME THAT ITS IS THE INSTRUMENT CLUSTER AND NEEDS TO BE REPLACED. THIS IS A HAZARD AS WHEN IT STOPS WORKING, I HAVE KNOW IDEA AS TO MY SPEED. IT IS MY UNDERSTANDING THAT THIS IS A KNOW PROBLEM BY GM AND THEY OFFERED A EXTENDED FIX OPTION, BUT DID NOT NOTIFY GM OWNERS OF THIS HAZARD. *TR

NHTSA ODI #10415184

189,000 miles · Jun 19, 2011
Service Brakes, Hydraulic

WIFE AND CHILD DRIVING TRUCK, BRAKE PEDAL WENT TO THE FLOOR AND SERVICE BRAKE INDICATOR CAME ON WHILE ON INTERSTATE. STOPPED AT A GAS STATION AND FILLED MASTER CYLINDER RESERVOIR WITH FLUID. DROVE VEHICLE 8 MORE MILES AND TRADED WITH ME, WHEN I GOT TO THE VEHICLE, I FOUND BRAKE FLUID LEAKING ONTO GROUND, FOUND LINES CORRODED BEY…

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WIFE AND CHILD DRIVING TRUCK, BRAKE PEDAL WENT TO THE FLOOR AND SERVICE BRAKE INDICATOR CAME ON WHILE ON INTERSTATE. STOPPED AT A GAS STATION AND FILLED MASTER CYLINDER RESERVOIR WITH FLUID. DROVE VEHICLE 8 MORE MILES AND TRADED WITH ME, WHEN I GOT TO THE VEHICLE, I FOUND BRAKE FLUID LEAKING ONTO GROUND, FOUND LINES CORRODED BEYOND BELIEF ON DRIVER SIDE FRAME AROUND WHEEL WELL. DROVE TRUCK HOME USING EMERGENCY BRAKE, LOW SPEED, AND DOWN SHIFTING. NO REPAIRS HAVE BEEN PERFORMED DUE TO STRONG BELIEF THIS IS A MANUFACTURER DEFECT. *TR

NHTSA ODI #10407413

38,000 miles · May 31, 2011
Engine And Engine Cooling

LEFT AND RIGHT SIDES REAR EXHAUST MANIFOLD BOLTS BROKEN OFF. IT LEAKS EXHAUST, MAY BE A FIRE HAZARD AND COULD CAUSE EMISSIONS FAILURE AND EMISSIONS COMPONENTS FAILURES. THIS PROBLEM IS ON A 2004 GMC 6.0 ENGINE. NOTICED TICKING NOISE AT ABOUT 38000 MILES AND IT WOULD GO AWAY AFTER 30-45 SECONDS. A GM REP SAID IT WAS MOST LIKE…

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LEFT AND RIGHT SIDES REAR EXHAUST MANIFOLD BOLTS BROKEN OFF. IT LEAKS EXHAUST, MAY BE A FIRE HAZARD AND COULD CAUSE EMISSIONS FAILURE AND EMISSIONS COMPONENTS FAILURES. THIS PROBLEM IS ON A 2004 GMC 6.0 ENGINE. NOTICED TICKING NOISE AT ABOUT 38000 MILES AND IT WOULD GO AWAY AFTER 30-45 SECONDS. A GM REP SAID IT WAS MOST LIKELY THE SKIRT LESS PISTONS AND NOT TO WORRY. HAD SOME WORK DONE AT A GARAGE ABOUT A WEEK AGO AND MECHANIC POINTED OUT THE BROKEN BOLTS. *TR

NHTSA ODI #10403940

Mileage unknown · Apr 27, 2011
Electrical System

IM THE OWNER OF A 2004 GMC HD SIERRA TRUCK WITH ALMOST 74K MILES. IM THE ORIGINAL OWNER. SOME MONTHS BACK THE GAS GAUGE STATED SHOWING GAS READINGS WAY BEYOND FULL.IT WOULD STAY THAT WAY FOR SOME TIME BEFORE GOING BACK TO NORMAL THAN IT WOULD FAIL AGAIN. LAST WEEK THE SPEEDOMETER GAUGE WENT BEYOND THE 120 MILE READING AND CONTIN…

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IM THE OWNER OF A 2004 GMC HD SIERRA TRUCK WITH ALMOST 74K MILES. IM THE ORIGINAL OWNER. SOME MONTHS BACK THE GAS GAUGE STATED SHOWING GAS READINGS WAY BEYOND FULL.IT WOULD STAY THAT WAY FOR SOME TIME BEFORE GOING BACK TO NORMAL THAN IT WOULD FAIL AGAIN. LAST WEEK THE SPEEDOMETER GAUGE WENT BEYOND THE 120 MILE READING AND CONTINUES TO SHOW HIGH SPEEDS -EVEN WHEN IM PARKED. IM CONCERN ABOUT DANGER THIS FAILURES MAY CAUSE TO ME OR OTHER DRIVERS ON THE ROAD. I WILL CONTACT MY LOCAL GMC DEALER FOR A FIX. *TR

NHTSA ODI #10397980

60,000 miles · Apr 16, 2011
Engine And Engine Cooling

BOLTS THAT HOLD EXHAUST MANIFOLD ARE BREAKING 3 ARE GONE ALREADY I JUST NOTICED IT TODAY BECAUSE I HEARD AN EXHAUST LEAK UNKNOWN HOW LONG THIS HAS BEEN GOING ON. *TR

NHTSA ODI #10396092

Official recalls

1

04V562000 · Equipment Adaptive/mobility

Nov 26, 2004

ON CERTAIN VANS EQUIPPED WITH SURE-LOK WHEELCHAIR SECUREMENT SYSTEMS, THE SPROCKET TEETH OF THE RETRACTOR ASSEMBLY IS OUT OF ALIGNMENT.

Consequence & remedy

Consequence: IN THE EVENT OF A VEHICLE CRASH, THE WHEELCHAIR MAY NOT BE ADEQUATELY SECURED POSSIBLY RESULTING IN INJURIES TO A WHEELCHAIR OCCUPANT.

Remedy: DEALERS WILL INSPECT AND REPLACE THE WHEELCHAIR SECUREMENT RETRACTORS AS NECESSARY. SURE-LOK WILL HANDLE THE REPAIRS FOR THIS CAMPAIGN. OWNERS SHOULD CONTACT SURE-LOCK AT 1-908-231-1804 OR MOBILITYWORKS AT 1-800-769-8267.

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.