NHTSA vehicle safety data

2004 Chevrolet Silverado 2500 Recalls & Complaints

The 2004 Chevrolet Silverado 2500 has 2 NHTSA recall campaigns and 85 owner complaints on file as of November 3, 2026. Recall repairs are usually free at an authorized Chevrolet dealer.

NHTSA recall and complaint data for the 2004 Chevrolet Silverado 2500. Recall data is refreshed daily from NHTSA.

Pre-purchase inspection checklist → Reliability & 5-year cost forecast →

2004 Chevrolet Silverado 2500 owner complaints

Owners have filed 85 complaints with NHTSA about the 2004 Chevrolet Silverado 2500, describing incidents dated August 31, 2004 to May 29, 2026.

Most-cited components

Service Brakes 35 complaints
Electrical System 24 complaints
Engine 9 complaints
Fuel/Propulsion System 7 complaints
Steering 6 complaints
Power Train 5 complaints

Of the 85 complaints on file, 7 report a crash and 3 a fire; across all 85 complaints, owners report 4 injuries (owner-reported, not verified by NHTSA).

Newest complaints

ODI #11742282 · Filed June 5, 2026
The contact owns a 2004 Chevrolet Silverado 2500. The contact stated that while driving 60-65 MPH, the vehicle experienced reduced power and went into LIMP Mode. The contact pulled over to the side of the road. The contact turned off and restarted the vehicle after several minutes, as per the…
ODI #11561107 · Filed December 20, 2023
Hydraboost piston blew out, lost brakes and steering. Almost wrecked vehicle.
ODI #11440880 · Filed November 18, 2021
The transfer case wore a pine hole in the case from the oil pump spring lock not securing movement causing me to loose all oil from transfer case. This left me stranded when I could not shift into 4 wheel drive the could not get it to re- engage 2wheel drive. This could have possibly caused…

Read all 85 complaints

Owner-reported

2004 Chevrolet Silverado 2500 mileage at failure

75 of the 85 complaints on file for the 2004 Chevrolet Silverado 2500 give the vehicle's mileage when the problem happened.

Mileage at failure by component, from owners' complaints to NHTSA
Component	Median	Middle half	Based on
Service Brakes	Median 95,000 miles	Middle half 65,000–130,000 miles	Based on 34 complaints

A component's median is its 50th percentile, and its middle half runs from its 25th to its 75th percentile.

Owners give the mileage themselves, often as a round number, and NHTSA doesn't check it. A complaint that names several components counts under each one, and mileages that can't be right, such as 999,999, or 50 miles on a five-year-old car, are left out.

These figures describe the complaints owners filed. They don't predict when a particular vehicle will have a problem, and vehicles that never had one aren't counted.

Mileage from NHTSA's complaints file of October 31, 2026. How these figures are worked out

AFTERMARKET FUEL FILTERS/FUEL LEAK

NHTSA #06E043000 · Fuel System, Gasoline · NHTSA notice

Reported May 19, 2006 · HONEYWELL INTERNATIONAL, INC.

Potentially affected: 88,303 vehicles

Owners notified October 18, 2006

Defect description

CERTAIN REPLACEMENT FUEL FILTERS, FRAM BRAND NAME P/N G3727, WITH DATE CODES X52911 THROUGH X60801 SEQUENTIALLY OR X600141 AND A MEXICO COUNTRY OR ORIGIN MARKING ON THE FUEL FILTER HOUSING MANUFACTURED FROM OCTOBER 18, 2005, THROUGH MARCH 21, 2006, SOLD FOR USE ON THE VEHICLES LISTED ABOVE AND ON CERTAIN SCHOOL BUSES. (TO SEE THE SCHOOL BUS ENGINE SIZES, CLICK ON "DOCUMENT SEARCH" AND THEN "BUS APPLICATIONS"). THE CONNECTOR ON THE FUEL FILTER WAS NOT MANUFACTURED TO HONEYWELL'S SPECIFICATION. AS A RESULT, THE O-RING MAY NOT SEAT CORRECTLY ON THE FUEL LINE.

Safety consequence

THIS CONDITION MAY CAUSE AN INADEQUATE SEAL AT THE CONNECTION, POTENTIALLY LEADING TO A FUEL LEAK. IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.

Manufacturer remedy

HONEYWELL WILL NOTIFY OWNERS AND REPLACE THE FUEL FILTERS FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 18, 2006. OWNERS MAY CONTACT FRAM CUSTOMER SERVICE AT 1-800-890-2075 (OPTION 1).

Notes

THIS RECALL ONLY PERTAINS TO AFTERMARKET FRAM FUEL FILTERS AND HAS NO RELATION TO ANY ORIGINAL EQUIPMENT INSTALLED ON THE VEHICLES LISTED.CUSTOMERS MAY CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.

AFTERMARKET REPLACEMENT PITMAN ARM

NHTSA #06E010000 · Steering · NHTSA notice

Reported February 1, 2006 · FABTECH MOTORSPORTS

Potentially affected: 1,360 vehicles

Defect description

CERTAIN FABTECH AFTERMARKET REPLACEMENT PITMAN ARMS, P/NOS. FTS71000 AND FTS71001, INSTALLED FOR USE ON CERTAIN 2001-2006 GM C/K 2500 PICK UP TRUCKS AND SPORT UTILITY VEHICLES. THE PIN LOCATED INSIDE THE PITMAN ARM CAN SHEAR OFF DUE TO A REVERSE BENDING FATIGUE CONDITION, RESULTING IN A TOTAL LOSS OF STEERING CONTROL.

Safety consequence

LOSS OF STEERING CONTROL COULD LEAD TO A VEHICLE CRASH WITH POTENTIAL INJURY OR DEATH.

Manufacturer remedy

FABTECH WILL NOTIFY OWNERS AND REPLACE THE PITMAN AND IDLER ARMS FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING FEBRUARY 2006. OWNERS MAY CONTACT FABTECH AT 909-597-7800.

Notes

THIS RECALL ONLY PERTAINS TO AFTERMARKET FABTECH REPLACEMENT PITMAN ARMS AND HAS NO RELATION TO ANY ORIGINAL EQUIPMENT INSTALLED ON C/K 2500 PICK UPS, SUVS, AND HUMMER H2 VEHICLES MANUFACTURED BY GENERAL MOTORS.CUSTOMERS MAY CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.

try.vin has no NCAP crash-test rating on file for the 2004 Chevrolet Silverado 2500. NHTSA rates some vehicles by body style — pickups by cab, vans by roof height — so check nhtsa.gov/ratings.

85 owner complaints have been filed with NHTSA for the 2004 Chevrolet Silverado 2500.

Power Train

ODI #11742282

Incident: May 29, 2026 · Filed: June 5, 2026

The contact owns a 2004 Chevrolet Silverado 2500. The contact stated that while driving 60-65 MPH, the vehicle experienced reduced power and went into LIMP Mode. The contact pulled over to the side of the road. The contact turned off and restarted the vehicle after several minutes, as per the Owner's Manual. The transmission warning light was illuminated. The vehicle was taken to the dealer to be diagnosed. The contact was informed that it could take 1-2 weeks to diagnose the vehicle, and several months to repair the vehicle. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure, and a claim was filed. The failure mileage was approximately 50,000.

Steering; Service Brakes

ODI #11561107

Incident: December 18, 2023 · Filed: December 20, 2023

Hydraboost piston blew out, lost brakes and steering. Almost wrecked vehicle.

Power Train

ODI #11440880

Incident: November 7, 2021 · Filed: November 18, 2021

The transfer case wore a pine hole in the case from the oil pump spring lock not securing movement causing me to loose all oil from transfer case. This left me stranded when I could not shift into 4 wheel drive the could not get it to re- engage 2wheel drive. This could have possibly caused catastrophic loss of control had the transfer case locked up while driving at high speed on slick roads or if someone ran into me from sudden lock up of the drive train.

Tires

ODI #11278861

Incident: July 2, 2019 · Filed: November 8, 2019

TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500 EQUIPPED WITH PRIMEWELL VALERA HT HARRY TRUMAN TIRES, SIZE: LT265/75/R16 (NA). WHILE DRIVING VARIOUS SPEEDS, THE VEHICLE SHOOK. THE CONTACT TOOK THE VEHICLE TO AN INDEPENDENT MECHANIC TO HAVE ALL THE TIRES REPLACED ON TWO SEPARATE OCCASIONS; HOWEVER, THE FAILURE CONTINUED. THE CONTACT WAS INFORMED THAT THE TIRES WERE DEFECTIVE AND COULD NOT BE BALANCED CORRECTLY. THE DEALER AND MANUFACTURER WERE NOTIFIED OF THE FAILURE. THE TIRE AND VEHICLE FAILURE MILEAGE WAS UNKNOWN.

Electrical System; Vehicle Speed Control; Fuel/Propulsion System

ODI #11163966

Incident: August 22, 2018 · Filed: December 29, 2018

CHECK ENGINE LIGHT CAME ON AND "LOW ENGINE POWER" FLASHED WHERE THE ODOMETER IS. THIS CAUSED THE RPM'S NOT TO GO OVER 2800. CODE READER CLAIMS O2 SENSORS OR THROTTLE CONTROL MODULE OR CATALYTIC CONVERTOR ISSUES. WE DISCOVERED IT WAS NONE OF THE ABOVE. TO FIX PROBLEM CHANGE 3 RELAYS LOCATED UNDER HOOD IN FUSE BOX. RELAY #8864. THEN CLEAR CODES, SHOULD FIX ISSUE UNLESS CODE PERSISTS. RELAYS WILL CAUSE A FIRE IF NOT CHANGED OUT ASAP.

Wheels

ODI #11151895

Incident: September 22, 2018 · Filed: November 16, 2018

DRIVING SOUTH ON INTERSTATE 15 IN #1 LANE SOUTH OF CEDAR CITY, UTAH. THE TRUCK SUDDENLY SHOOK VIOLENTLY AND WITHIN SECONDS THERE WAS A LOUD EXPLOSION WITH DEBRIS FLY A HEAD OF ME. I FOUGHT TO CONTROL MY VEHICLE AND WAS ABLE TO SLOW DOWN TO PULL OFF ON THE SHOULDER OF THE ROAD WITH HITTING ANY ONE. THE TIRE THAT EXPLODED WAS ON LEFT FRONT. THE ENTIRE TREAD CAME OFF OF THE TIRE AND TIRE SEPARATED WHERE THE TIRE WAS SEAMED TOGETHER DURING MANUFACTURE. THERE WAS EXTENSIVE DAMAGE TO THE VEHICLE BENT FRONT BUMPER, TORE THE WHEEL WELL LINER, DENTED THE FRONT DOOR IN SEVERAL PLACES AND DENTED ROCKER PANEL UNDER THE FRONT DOOR. THE TIRE WAS A BF GOODRICH ALL TERRAIN T/A KO, LT285R70/17 LOAD RANGE E. THE TIRE HAD A 50,000 MILE WARRANTY BUT HAD JUST A LITTLE 20,000 MILES WITH 10/32 TREAD ON ALL TIRES WHICH MEANS THERE WAS 60% TREAD LIFE LEFT IN THE TIRES. WHEN I WAS ALMOST HOME, I NOTICE A TYPE OF VIBRATION LIKE A TIRE WAS UNBALANCE OR OUT OF ROUND. I CHECK THE OTHER THREE TIRES AND DISCOVERED THE RIGHT REAR TIRE HAD LARGE BULGE ACROSS THE TREAD WHICH INDICATES THAT ANOTHER TIRE WAS FAILING. TOOK THE TIRES TO THE DEALER AND TOLD ME THAT ME THESE FAILURES WERE DO TO A MANUFACTURER/WORKMANSHIP DEFECT. MICHELIN WHICH MAKES THE BF GOODRICH TIRES WANTS ME TO PAY FOR A NEW SET OF TIRES AND DAMAGE TO MY TRUCK AND VERBALLY THEY TELL ME THEY MAY REIMBURSE ME BUT WILL NOT PUT THAT IN WRITING. I DO NOT TRUST THEM AND WILL NEVER BUY BF GOODRICH OR MICHELIN TIRES AGAIN. MICHELIN HAS A RECALL ON THIS LINE OF TIRES IN VARIOUS SIZES BUT NOT IN MY SIZE. DO NOT UNDERSTAND WHY MY SIZE WAS NOT RECALLED BECAUSE ALL SIZES IN THE ALL TERRAIN LINE ARE MADE WITH THE SAME MATERIALS AND MANUFACTURING PROCESS THE SAME FOR ALL SIZES. THE ONLY DIFFERENCE IS THE SIZE OF THE TIRE.

Electrical System

ODI #11072174

Incident: February 10, 2018 · Filed: February 11, 2018

MANY OF THE VEHICLES IN THIS FAMILY SUFFER FROM RANDOM ELECTRICAL SHORTS AND OR POOR ELECTRICAL GROUNDING RELATING TO THE DRIVE BY WIRE THROTTLE ACTUATOR. THE RESULT IS THAT THE VEHICLE WILL GO INTO 'REDUCED ENGINE POWER' MODE RANDOMLY. IN THIS MODE THE VEHICLE WILL IDLE BUT NOT ACCELERATE OR DRIVE. THIS ISSUE IS WELL DOCUMENTED ON MESSAGE BOARDS WITH NO CONSISTENT FIX. THIS CONDITION EXPOSES AN EXTREME HAZARD AS THE VEHICLE CAN LOOSE POWER AT ANY TIME. THIS IS A SERIOUS SAFETY ISSUE THAT SHOULD BE INVESTIGATED. I HAVE HAD MY VEHICLE LOOSE POWER ON THE INTERSTATE AND ON HIGH SPEED 2 LANE ROADS WITH NO SHOULDER AND HEAVY TRAFFIC ON 4 OCCASIONS. NUMEROUS ATTEMPTS TO REPAIR THE ISSUE HAVE BEEN UNSUCCESSFUL.

Electrical System

ODI #11047326

Incident: May 20, 2016 · Filed: November 19, 2017

MAY 2016 INSTALLED 5 YEARS WARRANTY BATTERY. BATTERY DEAD EVERY THREE MONTH. CHARGED BATTERY. INSTALLED NEW BATTERY LAST WEEK. BATTERY DEAD TODAY. HAD ALTERNATOR TESTED. (FINE) NOTICE DASHBOARD LIGHT WHERE READ MILAGE LOOKED LIKE THIS AFTER TRUCK OFF #######. ONLY GREEN LIGHT WILL NOT TURN OFF

Service Brakes

ODI #11023738

Crash

Incident: August 29, 2017 · Filed: September 16, 2017

TOTAL BRAKE FAILURE WHEN ATTEMPTING TO SLOW/STOP VEHICLE TO MAKE A TURN. DROVE INTO PARKING LOT TO GET OFF OF ROADWAY, HIT SIGN, TREE, PARKED VEHICLE BEFORE VEHICLE FINALLY STOPPED.

Power Train; Service Brakes; Engine

ODI #10954870

Incident: August 22, 2016 · Filed: February 15, 2017

ENGINE RUNS ROUGH AT IDLE.CK ENGINE LIGHT ON.

Other Chevrolet Silverado 2500 model years

Check your 2004 Chevrolet Silverado 2500 VIN

Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your Chevrolet Silverado 2500 at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.

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