NHTSA vehicle safety data

2004 Chevrolet W3500 Recalls & Complaints

The 2004 Chevrolet W3500 has 1 NHTSA recall campaign and 4 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 W3500. Recall data is refreshed daily from NHTSA.

2004 Chevrolet W3500 owner complaints

Owners have filed 4 complaints with NHTSA about the 2004 Chevrolet W3500, describing incidents dated July 5, 2004 to August 1, 2014.

Most-cited components

Engine 2 complaints
Electrical System 1 complaint
Fuel/Propulsion System 1 complaint
Service Brakes 1 complaint
Structure 1 complaint
Suspension 1 complaint

Newest complaints

ODI #10622124 · Filed August 13, 2014
THE BOLTS ATTACHING THE EXHAUST MANIFOLD TO THE ENGINE ARE BROKEN OFF CAUSING EXHAUST LEAKS BOTH SIDE MOTOR. THE CAB OF THIS VEHICLE SITS OVER THE MOTOR SO YOU CAN SMELL RAW EXHAUST INSIDE THE VEHICLE.. THERE ARE SEVERAL COMPLAINTS POSTED ONLINE AND YOUTUBE ABOUT THIS PROBLEM. I HAVE A FRIEND THAT…
ODI #10395710 · Filed April 13, 2011
TL*THE CONTACT OWNS A 2004 CHEVROLET C3500 TRUCK. THE CONTACT STATED THAT THE EXHAUST SYSTEM IS LEAKING. FUMES EMITTED THROUGHOUT THE CABIN WHEN THE ENGINE WAS IN OPERATION. THE CONTACT WAS IN THE PROCESS OF PERFORMING A DIAGNOSTIC TEST TO DETERMINE THE CAUSE OF FAILURE. THE FAILURE MILEAGE WAS…
ODI #10191611 · Filed May 24, 2007
VEHICLE WAS TOWING A TRAILER. WHEN THE LEFT REAR SHOCK MOUNT BROKE OFF THE AXLE. THE BRAKE LINE IS BOLTED TO THE SHOCK MOUNT. WHEN THE MOUNT BROKE, IT TOOK OUT THE BRAKE LINE, WATCH RESULTED IN THE LOSE OF BRAKES. AFTER HAVING A WELDER LOOK AT THE BRACKET WE CAME TO THE CONCLUSION THAT THE WELDS…

Read all 4 complaints

DUAL FUEL TANK

NHTSA #05V168000 · Fuel System, Diesel — Storage — Tank Assembly · NHTSA notice

Reported April 20, 2005 · ISUZU MANUFACTURING SERVICES OF AMERICA

Potentially affected: 253 vehicles

Manufacturer campaign 05053 · Owners notified October 27, 2005 · Vehicles built July 1, 2002 – July 31, 2004 (per NHTSA)

Defect description

ON CERTAIN TRUCKS EQUIPPED WITH RPO IK9, DUE TO INSUFFICIENT DURABILITY AND TESTING, THE FUEL SWITCHING MANIFOLD SOLENOIDS LACK WATER OR SALT INTRUSION RESISTANCE, WHICH CAN LEAD TO FAILURE OF ONE OR MORE SOLENOIDS. FUEL SWITCHING MANIFOLD SOLENOID FAILURE WILL CAUSE INCORRECT FUEL DELIVERY RESULTING IN FUEL OVERFLOW FROM THE FUEL FILLER NECK.

Safety consequence

OVERFLOW FUEL MAY RESULT IN HIGH AMOUNT OF DIESEL FUEL LEAKAGE. FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.

Manufacturer remedy

DEALERS WILL REPLACE THE SOLENOID VALVE ASSEMBLY WITH AN IMPROVED ASSEMBLY INCLUDING ADDITIONAL DETECTION CIRCUIT AND ENHANCED WATER RESISTANCE FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 27, 2005. OWNERS MAY CONTACT ISUZU AT 1-800-255-6727.

Notes

RECALL NO. 05053.CUSTOMERS MAY ALSO 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 W3500. NHTSA rates some vehicles by body style — pickups by cab, vans by roof height — so check nhtsa.gov/ratings.

4 owner complaints have been filed with NHTSA for the 2004 Chevrolet W3500.

Engine and Engine Cooling; Structure

ODI #10622124

Incident: August 1, 2014 · Filed: August 13, 2014

THE BOLTS ATTACHING THE EXHAUST MANIFOLD TO THE ENGINE ARE BROKEN OFF CAUSING EXHAUST LEAKS BOTH SIDE MOTOR. THE CAB OF THIS VEHICLE SITS OVER THE MOTOR SO YOU CAN SMELL RAW EXHAUST INSIDE THE VEHICLE.. THERE ARE SEVERAL COMPLAINTS POSTED ONLINE AND YOUTUBE ABOUT THIS PROBLEM. I HAVE A FRIEND THAT HAS A SIMILAR TRUCK TO MINE AND HE HAS SAME PROBLEM. *TR

Engine and Engine Cooling

ODI #10395710

Incident: March 18, 2011 · Filed: April 13, 2011

TL*THE CONTACT OWNS A 2004 CHEVROLET C3500 TRUCK. THE CONTACT STATED THAT THE EXHAUST SYSTEM IS LEAKING. FUMES EMITTED THROUGHOUT THE CABIN WHEN THE ENGINE WAS IN OPERATION. THE CONTACT WAS IN THE PROCESS OF PERFORMING A DIAGNOSTIC TEST TO DETERMINE THE CAUSE OF FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 152,000. UPDATED 05/24/11*LJ THE CONSUMER STATED THE VEHICLE HAS A CRACKED EXHAUST MANIFOLD. UPDATED 05/26/11

Suspension; Service Brakes, Hydraulic

ODI #10191611

Incident: May 22, 2007 · Filed: May 24, 2007

VEHICLE WAS TOWING A TRAILER. WHEN THE LEFT REAR SHOCK MOUNT BROKE OFF THE AXLE. THE BRAKE LINE IS BOLTED TO THE SHOCK MOUNT. WHEN THE MOUNT BROKE, IT TOOK OUT THE BRAKE LINE, WATCH RESULTED IN THE LOSE OF BRAKES. AFTER HAVING A WELDER LOOK AT THE BRACKET WE CAME TO THE CONCLUSION THAT THE WELDS FROM THE FACTORY WERE TO COLD TO PENETRATE THE BRACKET OR THE AXLE. WE PUT NEW BRAKE LINE ON AND REMOUNTED THE SHOCK BRACKET TO AXLE. WE REROUTED THE BRAKE LINE SO IT WAS NOT ON THE SHOCK MOUNT.

Fuel System, Gasoline; Electrical System

ODI #10094656

Incident: July 5, 2004 · Filed: September 29, 2004

WHILE DRIVING 65 MPH VEHICLE STALLED. VEHICLE WAS TOWED TO THE DEALER FOR INSPECTION, AND MECHANIC DETERMINED THAT FUEL PUMP, COMPUTER SENSOR, AND FUEL LINE NEEDED TO BE REPLACED ,AND REPLACED THEM. HOWEVER, THE PROBLEM RECURRED. *AK

Other Chevrolet W3500 model years

Check your 2004 Chevrolet W3500 VIN

Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your Chevrolet W3500 at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.

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