NHTSA vehicle safety data

2004 GMC Sierra 2500 Recalls & Complaints

The 2004 GMC Sierra 2500 has 4 NHTSA recall campaigns and 50 owner complaints on file as of November 3, 2026. Recall repairs are usually free at an authorized GMC dealer.

NHTSA recall and complaint data for the 2004 GMC Sierra 2500. Recall data is refreshed daily from NHTSA.

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

2004 GMC Sierra 2500 owner complaints

Owners have filed 50 complaints with NHTSA about the 2004 GMC Sierra 2500, describing incidents dated May 9, 2004 to November 27, 2021.

Most-cited components

Service Brakes 19 complaints
Electrical System 14 complaints
Engine 9 complaints
Fuel/Propulsion System 4 complaints
Air Bags 2 complaints
Steering 2 complaints

Of the 50 complaints on file, 3 report a crash and 3 a fire; across all 50 complaints, owners report 4 injuries and 1 death (owner-reported, not verified by NHTSA).

Newest complaints

ODI #11442070 · Filed November 30, 2021
Brakes lines failed under truck do to rusted out lines
ODI #11408360 · Filed April 16, 2021
EMERGENCY BRAKES DON'T ENGAGE
ODI #11154344 · Filed November 27, 2018
TL* THE CONTACT OWNS A 2004 GMC SIERRA 2500. WHILE DRIVING APPROXIMATELY 45 MPH, THE CONTACT NOTICED A LOT OF WHITE SMOKE EMERGING FROM THE TAIL PIPE. THE VEHICLE WAS PREVIOUSLY REPAIRED UNDER WARRANTY BY GWATNEY BUICK GMC (5700 LANDERS RD, NORTH LITTLE ROCK, AR 72117) FOR THE SAME FAILURE AS LISTED…

Read all 50 complaints

AFTERMARKET HUB ASSEMBLIES

NHTSA #06E050000 · Service Brakes, Air · NHTSA notice

Reported June 6, 2006 · FEDERAL-MOGUL CORPORATION

Potentially affected: 6,800 vehicles

Defect description

CERTAIN FEDERAL-MOGUL NATIONAL AND CARQUEST AFTERMARKET HUB ASSEMBLIES, P/N 515058, SOLD FOR USE ON 2001-2006 GENERAL MOTORS 1500 AND 2500 4WD TRUCKS. ON THE SUBJECT HUB ASSEMBLIES, THE ABS SENSOR CORD DEPARTS FROM THE HUB ASSEMBLY AT A 90 DEGREE ANGLE. AS A RESULT, THERE IS A FIT ISSUE WITH THE BRAKE ROTOR DUST SHIELD INTERFERING WITH THE ABS SENSOR CORD. IF THE HUB ASSEMBLY IS INSTALLED DESPITE THIS INTERFERENCE, THE GAP BETWEEN THE ABS SENSOR AND THE TONE WHEEL MAY BE ALTERED. THIS MAY WEAKEN THE OUTPUT OF THE ABS SENSOR. DIMINISHED OUTPUT COULD RESULT IN AN UNWANTED ABS ACTIVATION AT LOW SPEEDS AND STOPPING DISTANCE COULD BE AFFECTED.

Safety consequence

IF STOPPING DISTANCE IS LIMITED, A VEHICLE CRASH COULD OCCUR.

Manufacturer remedy

FEDERAL-MOGUL WILL NOTIFY ITS OWNERS AND WILL EITHER CREDIT THE CUSTOMERS ACCOUNT OR REPLACE THE UNIT. THE RECALL IS EXPECTED TO BEGIN DURING JUNE 2006. OWNERS CAN CONTACT FEDERAL-MOGUL CUSTOMER SERVICE AT 1-800-563-8507 EXT 3530.

Notes

THIS RECALL ONLY PERTAINS TO AFTERMARKET NATIONAL AND CARQUEST HUB ASSEMBLIES AND HAS NO RELATION TO ANY ORIGINAL EQUIPMENT INSTALLED ON 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.

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.

MOBILITY WORKS/SURE-LOK/WHEELCHAIR SECUREMENT

NHTSA #04V562000 · Equipment Adaptive/Mobility · NHTSA notice

Reported November 26, 2004 · MOBILITY WORKS

Potentially affected: 1,660 vehicles

Manufacturer campaign 04E-058 · Vehicles built January 1, 1997 – August 1, 2004 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

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

Safety consequence

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

Manufacturer 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.

Notes

SURE-LOK RECALL NO. 04E-058.CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

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

50 owner complaints have been filed with NHTSA for the 2004 GMC Sierra 2500.

Service Brakes

ODI #11442070

Incident: November 27, 2021 · Filed: November 30, 2021

Brakes lines failed under truck do to rusted out lines

Service Brakes

ODI #11408360

Incident: January 11, 2021 · Filed: April 16, 2021

EMERGENCY BRAKES DON'T ENGAGE

Engine and Engine Cooling

ODI #11154344

Incident: November 27, 2018 · Filed: November 27, 2018

TL* THE CONTACT OWNS A 2004 GMC SIERRA 2500. WHILE DRIVING APPROXIMATELY 45 MPH, THE CONTACT NOTICED A LOT OF WHITE SMOKE EMERGING FROM THE TAIL PIPE. THE VEHICLE WAS PREVIOUSLY REPAIRED UNDER WARRANTY BY GWATNEY BUICK GMC (5700 LANDERS RD, NORTH LITTLE ROCK, AR 72117) FOR THE SAME FAILURE AS LISTED IN AN UNKNOWN TECHNICAL SERVICE BULLETIN REGARDING THE FUEL INJECTORS. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED FOR THE RECENT FAILURE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 90,000.

Engine

ODI #11142993

Incident: August 28, 2018 · Filed: October 26, 2018

EXHAUST MANIFOLD BOLTS BROKEN

Service Brakes

ODI #11018937

Incident: August 7, 2016 · Filed: August 22, 2017

I WAS TRAVELING SOUTH ON I-75 HIGHWAY ABOUT 70 MPH, IN MOTION, IN NORTHERN MICHIGAN AND HAD TO STOP FAST WHEN AN ACCIDENT OCCURRED IN FRONT OF ME. I SLAMMED/MASHED MY FOOT ON THE BRAKE PEDAL ONLY TO FEEL IT FALL TO THE FLOOR, THE METAL HYDRAULIC LINE FAILED AND I NOW HAVE NO BRAKES AT ALL!! I BEGAN TO PRESS ON THE PARKING BRAKE AND DOWN SHIFT THE TRANSMISSION TO ASSIST IN THE SLOWING OF THE VEHICLE. I ALSO STEERED AROUND THE STOPPED CARS INTO THE SIDE AND DITCH OF THE ROAD. I LUCKILY HAD THE RIGHT REACTIONS BUT NOT ALL PEOPLE DO OR CANNOT ACT AS FAST. THIS IS A DANGEROUS ISSUE WITH THIS GMC SIERRA 2004. PLEASE HAVE IT RECALLED. I HAD TO HAVE THE REPAIR SHOP REPLACE ALL THE METAL BRAKE LINES AS THEY WERE CORRODED. I HAVE NEVER HAD A VEHICLE FAIL ITS BRAKE LINES LIKE THIS. MY VEHICLE ONLY HAS 48,000 MILES ON IT AND IS GARAGE KEPT SUPER CLEAN.

Engine; Fuel/Propulsion System

ODI #10928882

Incident: November 26, 2016 · Filed: November 30, 2016

TL* THE CONTACT OWNS A 2004 GMC SIERRA 2500. THE CONTACT STATED THAT THE VEHICLE HAD A MASSIVE OIL LEAK. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE FUEL INJECTORS WERE DEFECTIVE, WHICH FILLED THE CRANKCASE FULL OF FUEL AND WAS A KNOWN ISSUE. THE VEHICLE WOULD HAVE BEEN REPAIRED PER AN EXTENDED WARRANTY; HOWEVER, IT FELL OUTSIDE OF THE PARAMETERS OF THE EXTENDED WARRANTY, INCREASING THE RISK OF AN ENGINE COMPARTMENT FIRE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 112,000.

Service Brakes; Fuel/Propulsion System

ODI #10850103

Incident: March 16, 2016 · Filed: March 16, 2016

IN THE PAST THREE MONTHS THE FUEL LINES NEEDED REPLACEMENT AS THEY HAD RUSTED SO BADLY THAT A LEAK FORMED. YESTERDAY WHILE PULLING MY 10,000 POUND BOAT, MY BRAKES SUDDENLY FAILED BECAUSE OF A LEAK IN THE LINE BETWEEN THE ABS BOX AND THE RIGHT FRONT WHEEL. THE CATASTROPHIC FAILURE NEARLY CAUSED ME TO LOSE CONTROL OF MY VEHICLE AND BOAT. I WAS ABLE TO DOWNSHIFT AND USE BY EMERGENCY BRAKE TO BRING THE RIG TO A STOP.

Service Brakes

ODI #10839852

Incident: March 1, 2016 · Filed: March 4, 2016

I LIVE IN SOUTH EAST MA. WERE SAULT IS USE ALWAYS AND IT HAS ROTTED MY BRAKE LINES AT THE ABS CONTROLL A LINE LET GO ON MY TRUCK WITH FAMILY AND MY GRAND BABIES I AM A HEAVY TRUCK OPERATOR WITH A CDL SO I KNOW NOT TO PANIC I GOT MY TRUCK STOPPED WITHOUT A CRASH BUT IF MY WIFE WAS DRIVEING OR MY YOUNG DAUGHTER THEY WOULDNT BE SO LUCKY WE IN THE SAULTING STATES SHOULD HAVE STANELESS STEAL FOR SAFTY CANT BE TO MUCH TO ASK FOR YOUNG LIFES AT STAKE OR PEOPLE WHO PANIC WHAT SHOULD I DO AT THE TIME I WAS IN THE CITY OF TAUNTON I WAS COMING TO A HEAVILY TRAVELED STREET IN RUSH HOUR TRAFIC THE BRAKE LINE TO REAR BRAKES FALLED BECAUSE OF ROT ON INSPION I SEE THEY ARE ALL ROTTING AND NEED TO BE REPAIRED I DONT HAVE BODY ROT OR FRAME ROT OF ANY KIND ALWAYS CAR WASH AFTER STORMS ON NICE DAYS.

Service Brakes

ODI #10746973

Incident: July 24, 2015 · Filed: August 7, 2015

TL* THE CONTACT OWNS A 2004 GMC 2500. THE CONTACT STATED THAT THE EMERGENCY BRAKE WAS INOPERABLE. THE CONTACT MENTIONED THAT THE PARKING BRAKE WAS DEPRESSED AND AN ABNORMAL NOISE EMITTED FROM THE UNDER CARRIAGE OF THE VEHICLE. THE CONTACT BELIEVED THAT THE PARKING BRAKE CABLE WAS FRACTURED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 197,000.

Structure

ODI #10743282

Incident: January 15, 2014 · Filed: July 24, 2015

TL* THE CONTACT OWNS A 2004 GMC SIERRA 2500. THE CONTACT OBSERVED CORROSION ON THE FRONT AND REAR BUMPERS. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 60,000.

Other GMC Sierra 2500 model years

Check your 2004 GMC Sierra 2500 VIN

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

Check a GMC VIN