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NHTSA vehicle safety data

2004 Chevrolet W4500 Recalls & Complaints

The 2004 Chevrolet W4500 has 1 NHTSA recall campaign and 1 owner complaint 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 W4500. Recall data is refreshed daily from NHTSA.

2004 Chevrolet W4500 owner complaints

Owners have filed 1 complaint with NHTSA about the 2004 Chevrolet W4500, describing incidents dated September 20, 2007.

Most-cited components

  • Fuel/Propulsion System 1 complaint

Newest complaints

  • ODI #10205431 · Filed

    ON SEVERAL OCCASIONS WITH THE TRUCK THERE HAVE BEEN SIGNIFICANT AMOUNTS OF SMOKE BELLOWING FROM THE EXHAUST. IN SOME CASES, OTHER AUTOS BELIEVE THE VEHICLE WAS ON FIRE. INJECTORS HAVE BEEN FOUND TO BE FAULTY ON THREE OCCASIONS REQUIRING REPLACEMENT AT SIGNIFICANT COSTS. SMOKE FROM THE EXHAUST IS DUE…

Read the full complaint

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.

Other Chevrolet W4500 model years

Check your 2004 Chevrolet W4500 VIN

Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your Chevrolet W4500 at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.

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