2004 Chevrolet Silverado 3500 problems

SERVICE BRAKES

ALL FACTORY HARD BRAKE LINES HAVE FAILED DUE TO CORROSION. I'VE REPLACED THE INTERMEDIATE LINE BETWEEN THE MASTER CYLINDER AND DISTRIBUTION BLOCK WITH STAINLESS STEEL 1.5 YRS AGO. I JUST REPLACED THE REAR BRAKE LINES ALONG THE AXEL. NOW THE FRONT BRAKE LINES HAVE FAILED. IN ALL CASES THE LINES FAILED WHILE DRIVING AND EMPTIED THE MASTER CYLINDER. I DO NOT LIVE IN THE SALT BELT.

NHTSA complaint #11023798 — an unverified report by a vehicle owner.

SERVICE BRAKES

BRAKE LINE FAILURE DUE TO RUSTED & CORRODED BRAKE LINES RESULTING IN COSTLY REPAIRS. LUCKILY MY 2004 CHEVY SILVERADO 3500 WAS STATIONARY WHEN BRAKE LINE RUPTURED AND I WAS NOT TOWING A TRAILER OR LOADED WITH CARGO AT THE TIME OF FAILURE. THE ABS PUMP ALSO FAILED PRIOR TO LINE FAILURE. MY FATHER IN LAW HAD SIMILAR ISSUES WITH THE SAME MODEL YEAR 1500. WHY DOES GM NOT USE STAINLESS BRAKE LINES FOR SUCH AN IMPORTANT SAFETY COMPONENT.

NHTSA complaint #10927504 — an unverified report by a vehicle owner.

SERVICE BRAKES

2 PROBLEMS: 1- WHILE DRIVING WITH NO WARNING THE BRAKES FAILED. AFTER COASTING TO A STOP I NOTICED A BRAKE LINE HAD RUPTURED AT THE FRAME RAIL UNDER DRIVER AREA. I WAS ABLE TO CRIMP BRAKE LINE WITH A PAIR OF VICE GRIP PLIERS AND MOVE TRUCK TO A SAFE LOCATION FOR REPAIR. I BELIEVE THE BRAKE LINES USED ON THESE TRUCKS TO BE OF SUCH INFERIOR QUALITY THAT SUDDEN FAILURE IS A COMMON OCCURRENCE. 2- MY TRUCK HAS DUAL TANKS FOR DIESEL FUEL AND THEY HAVE WORKED SPORADICALLY FOR YEARS. I DID NOT SEE THIS AS A SAFETY ISSUE AS MUCH AS AN INCONVENIENCE. HOWEVER WHILE MY TRUCK WAS IDLING ON A HOT SUMMER DAY I NOTICED DIESEL FUEL DRIPPING OUT OF THE FRONT TANK FILLER CAP. APPARENTLY THE PUMP THAT PUMPS THE FUEL FROM THE REAR TANK TO THE FRONT TANK WAS RECEIVING A SIGNAL TO PUMP EVEN THOUGH THE FRONT TANK WAS COMPLETELY FILLED. IT WAS CONTINUING TO PUMP AND LEAKING THE FUEL OUT THE FILLER NECK. THIS SEEMS LIKE A SERIOUS SAFETY HAZARD TO ME. I DO NOT KNOW IF THE ROOT OF THE PROBLEM IS THE FLOAT THAT STICKS IN THE REAR TANK, THE SENDING UNITS THAT FAIL, A WIRING GROUND ISSUE OR SOME OTHER ELECTRONIC GLITCH. I DO KNOW ISSUES WITH DUAL TANK DURAMAX DIESEL TRUCKS ARE ABOUT AS COMMON AS THE TRUCK ITSELF IS. AFTER RESEARCHING ONLINE I REALIZED MANY OTHER OWNERS OF MY VEHICLE MODEL HAVE HAD BOTH OF THE EXACT SAME PROBLEMS SO I THOUGHT I SHOULD REPORT THEM.

NHTSA complaint #10849665 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

2 PROBLEMS: 1- WHILE DRIVING WITH NO WARNING THE BRAKES FAILED. AFTER COASTING TO A STOP I NOTICED A BRAKE LINE HAD RUPTURED AT THE FRAME RAIL UNDER DRIVER AREA. I WAS ABLE TO CRIMP BRAKE LINE WITH A PAIR OF VICE GRIP PLIERS AND MOVE TRUCK TO A SAFE LOCATION FOR REPAIR. I BELIEVE THE BRAKE LINES USED ON THESE TRUCKS TO BE OF SUCH INFERIOR QUALITY THAT SUDDEN FAILURE IS A COMMON OCCURRENCE. 2- MY TRUCK HAS DUAL TANKS FOR DIESEL FUEL AND THEY HAVE WORKED SPORADICALLY FOR YEARS. I DID NOT SEE THIS AS A SAFETY ISSUE AS MUCH AS AN INCONVENIENCE. HOWEVER WHILE MY TRUCK WAS IDLING ON A HOT SUMMER DAY I NOTICED DIESEL FUEL DRIPPING OUT OF THE FRONT TANK FILLER CAP. APPARENTLY THE PUMP THAT PUMPS THE FUEL FROM THE REAR TANK TO THE FRONT TANK WAS RECEIVING A SIGNAL TO PUMP EVEN THOUGH THE FRONT TANK WAS COMPLETELY FILLED. IT WAS CONTINUING TO PUMP AND LEAKING THE FUEL OUT THE FILLER NECK. THIS SEEMS LIKE A SERIOUS SAFETY HAZARD TO ME. I DO NOT KNOW IF THE ROOT OF THE PROBLEM IS THE FLOAT THAT STICKS IN THE REAR TANK, THE SENDING UNITS THAT FAIL, A WIRING GROUND ISSUE OR SOME OTHER ELECTRONIC GLITCH. I DO KNOW ISSUES WITH DUAL TANK DURAMAX DIESEL TRUCKS ARE ABOUT AS COMMON AS THE TRUCK ITSELF IS. AFTER RESEARCHING ONLINE I REALIZED MANY OTHER OWNERS OF MY VEHICLE MODEL HAVE HAD BOTH OF THE EXACT SAME PROBLEMS SO I THOUGHT I SHOULD REPORT THEM.

NHTSA complaint #10849665 — an unverified report by a vehicle owner.

STRUCTURE:BODY

TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 3500. THE CONTACT STATED THAT THE ROCKER PANELS LOCATED UNDER THE DOORS ON BOTH THE DRIVER AND PASSENGER SIDE OF THE VEHICLE WERE RUSTED AND CORRODED. THE VEHICLE WAS TAKEN TO THE DEALER WHO DID NOT REPAIR THE VEHICLE. THE CONTACT INDICATED THAT THE STEEL INSIDE THE ROCKER PANEL WAS NOT PAINTED AND CONTRIBUTED TO THE RUSTING. THE CAUSE OF THE FAILURE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN WAS NOT AVAILIABLE. THE FAILURE MILEAGE WAS 40,000.

NHTSA complaint #10837777 — an unverified report by a vehicle owner.

SERVICE BRAKES

IN MARCH WHILE DRIVING MY 2004 CHEVY 3500 DIESEL TRUCK THE BRAKE WARNING LIGHTS INSIDE THE CAB LIT UP AND THE BRAKE PEDAL WAS FEELING SPONGY. I TOOK IT INTO CLASSIC AUTO GROUP MENTOR FOR SERVICE. A WHEEL BEARING WAS REPLACED ALONG WITH A FEW OTHER ITEMS AND I WAS TOLD THAT IT WAS GOOD TO GO. I PICKED IT UP. THE BRAKE PEDAL WAS STILL SPONGY AND THE WARNING LIGHTS WERE STILL ON. ON APRIL 22, I RETURNED TO THE CLASSIC AUTO GROUP CHEVY SERVICE TO AGAIN HAVE THE BRAKES SERVICED. THEY BILLED ME $1400.00 TO CHANGE A VALVE, A MODULE AND SOME SCREWS. THE BRAKES NOW GO ALL THE WAY DOWN TO THE FLOOR WHEN DEPRESSED WITH THE MOTOR RUNNING. THERE IS NO EFFECTIVE BRAKING ABILITY. WITH NO EFFECTIVE BRAKING THE WARNING LIGHTS ARE NOT LIT UP. CLASSIC AUTO GROUP CHEVY IN MENTOR SAYS THAT THIS IS NORMAL. THIS IS NOT HOW THE BRAKES WORKED BEFORE THE WARNING LIGHTS CAME ON. THEY WORKED LIKE BRAKES ON ANY VEHICLE. CLASSIC AUTO GROUP MENTOR SAYS THAT I SHOULD JUST GET USED TO IT. I HAVE A COMPLAINT NUMBER FROM CHEVY # [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

NHTSA complaint #10713360 — an unverified report by a vehicle owner.

ENGINE

TICKING UNDER HOOD. EXHAUST LEAK DUE TO BROKEN EXHAUST MANIFOLD BOLT PASSENGER SIDE NEAR FIREWALL. TRIED TO LOOSEN OTHER BOLTS, 3 MORE BROKE. TRUCK HAS VERY LOW MILES, 8.1L MOTOR. INTERNET SHOWS THOUSANDS OF SAME ISSUES. BOLTS USED ARE VERY THIN FOR WHAT THEY DO.

NHTSA complaint #10705759 — an unverified report by a vehicle owner.

FUEL SYSTEM, GASOLINE

2004 CHEVROLET SILVERADO 3500. CONSUMER WRITES IN REGARDS TO ENGINE INJECTORS ISSUE. *SMD THE CONSUMER STATED THE INJECTORS WERE REPLACED IN 2010, AND NOW THEN NEED TO BE REPLACED AGAIN.

NHTSA complaint #10694538 — an unverified report by a vehicle owner.

SERVICE BRAKES

HAD JUST HOOKED UP OUR 38' - 12,000LB FIFTH WHEEL AND HEADED OUT FOR THE WEEKEND. CAME TO THE FIRST STOP SIGN AND THE BRAKE PEDAL WENT TO THE FLOOR. LUCKILY GOT STOPPED WITH TRAILER BRAKES. AFTER STOPPING, PUMPING BRAKES CAUSED BRAKE FLUID TO POUR OUT FROM JUST IN FRONT OF THE DRIVER'S SIDE REAR WHEEL. UPON RESEARCH WHEN WE ARRIVED HOME, I FIND THAT THIS IS AN ONGOING ISSUE WITH CHEVROLET TRUCKS.

NHTSA complaint #10537851 — an unverified report by a vehicle owner.

SERVICE BRAKES

BRAKES FAILED. CHINA MADE STEEL BRAKE LINES RUSTED OUT AND DISINTEGRATED. COULD HAVE BEEN KILLED. HAD TO GET REPAIR TO STEEL BRAKE LINES FROM ABS PUMP TO MASTER CYLINDER AND FRONT CALIPERS. ALSO MAKE UP AND REPLACE STEEL BRAKE LINE TO REAR AXLE AND TO REAR LEFT AND RIGHT REAR CALIPERS. ALSO HAD TO REPLACE BLEED SCREWS IN ALL CALIPERS.

NHTSA complaint #10498404 — an unverified report by a vehicle owner.

SERVICE BRAKES

WHILE DRIVING MY CHEVY SILVERADO 3500 DUALLY AT APPROXIMATELY 50 MPH, I HAD SO MAKE A SUDDEN EMERGENCY STOP. MY BRAKE PEDAL WENT TO THE FLOOR WITH VIRTUALLY NO STOPPING POWER FOR THE VEHICLE. I SWERVED OUT OF THE WAY TO AVOID AN ACCIDENT AND WAS VERY LUCKY. THE TRUCK WENT DIRECTLY TO THE REPAIR SHOP WHICH HAS INFORMED ME THAT THE BRAKE LINES ARE RUSTED THROUGH AND ALL NEED TO BE CHANGED. I CALLED THE CHEVY SUPPORT NUMBER TO REPORT THIS PROBLEM AND ASK ABOUT A RECALL. THE REP TOOK THE LAST EIGHT OF MY VIN NUMBER AND SAID THERE IS NO KNOWN PROBLEM WITH THE BRAKES ON THIS VEHICLE. I TOW HEAVY EQUIPMENT WITH THIS TRUCK FOR WORK, SO IT IS AN ALARMING SAFETY CONCERN FOR ME FOR THE BRAKES TO SUDDENLY NOT WORK WITHOUT WARNING. I AM LUCKY THAT NOBODY GOT KILLED DUE TO THIS PROBLEM.

NHTSA complaint #10484746 — an unverified report by a vehicle owner.

SERVICE BRAKES

COUNTY ROAD (THANK GOODNESS). DRIVING ABOUT 45 MPH WHEN A LADY TURNED OFF A SIDE ROAD IN FRONT OF ME. I STEPPED ON THE BRAKE PEDAL TO AVOID A REAR END COLLISION. THE BRAKE PEDAL HELD MOMENTARILY BUT THEN WENT TO THE FLOOR. I SWERVED RIGHT INTO THE DITCH AND USED THE EMERGENCY BRAKE TO KEEP FROM STRIKING HER CAR IN THE REAR. IN ORDER TO GET THE VEHICLE HOME (APPROXIMATELY 3 MILES), I HAD TO USE THE EMERGENCY BRAKE TO STOP. COULD NOT AFFORD TO GET THE TRUCK TO THE DEALERSHIP (APPROXIMATELY 15 MILES AWAY IN HEAVY SUBURBAN TRAFFIC) FOR DIAGNOSIS AND REPAIR. SAVED UP AND TOOK THE TRUCK TO A LOCAL MECHANIC (09/2012). MECHANIC ASK IF THE TRUCK HAD EVER BEEN UNDER WATER. REASON FOR QUESTION WAS THE BRAKE LINES, FRONT CALIPERS, AND TOP FORWARD FRAME WERE SEVERELY RUSTED. THE BRAKE LINES RUSTED THROUGH CAUSING A BREAK FAILURE. THIS TRUCK HAS LESS THAN 21,000 MILES, NEVER BEEN SUBMERGED IN WATER, OCCASIONALLY DRIVEN IN THE WINTER, WASHED FREQUENTLY (ESPECIALLY IN THE WINTER) AND WAXED, AND HAS ZERO BODY OR BED RUST. AFTER REPAIR, THE ABS LIGHT CAME ON AND STAYS ON. I READ SOMEWHERE ON THIS SITE A BULLETIN REGARDING PREMATURE ABS SENSOR FAILURE AND DEALERS FIXING THE SENSORS BUT I CAN NOT FIND THE ABS BULLETIN NOW.

NHTSA complaint #10478470 — an unverified report by a vehicle owner.

ENGINE

IN JANUARY 2004, I BOUGHT A NEW CHEVY 3500 DURAMAX DIESEL TRUCK. SINCE MARCH 2005, I HAVE HAD TO HAVE THE INJECTORS REPLACED A TOTAL OF 6 TIMES. NOW AT 202,000 THE INJECTORS NEED REPLACED AGAIN. CHEVY WILL NOT HELP OUT ON THIS PROBLEM. I HAVE READ THAT EVERYONE SHOULD FILE A COMPLAINT WITH THIS DEPARTMENT SO THAT THIS CAN BE INVESTIGATED. IN NOVEMBER 2011, SOMEONE WAS TOLD THERE WERE NOT COMPLAINTS. BEING A CHEVY OWNER WITH THESE INJECTOR PROBLEMS, I AM WRITING TO COMPLAIN. HOPEFULLY, THIS DEPARTMENT WILL CONDUCT THE INVESTIGATION AND HELP ALL THE OTHER PEOPLE WITH THIS PROBLEM GET A RESPONSE FROM CHEVY TO DO SOMETHING. THESE TRUCKS ARE NOT CHEAP AND JUST BECAUSE WE USE OUR TRUCKS AND PUT MILES ON THEM, AND THEY HAVE REPEATED FAILURES, WE SHOULD NOT HAVE TO BEAR THE BURDEN. THIS PROBLEM WITH MY TRUCK IS IN THE DESIGN. HOW MANY PEOPLE REPLACE INJECTORS EVERY 30-40K MILES? THIS IS WHAT I HAVE HAD TO DO OVER THE LAST 7 YEARS.

NHTSA complaint #10463027 — an unverified report by a vehicle owner.

SERVICE BRAKES, HYDRAULIC

BRAKE LINE RUSTED AND FAILED WHILE DRIVING. HEAVY RUST ON SEVERAL BRAKE LINES, FRAME, AND CROSS MEMBERS.

NHTSA complaint #10456192 — an unverified report by a vehicle owner.

FUEL SYSTEM, DIESEL

CHEVY SILVERADO 3500 DURAMAX DIESEL, HAS A CRACKED FUEL FILTER HOUSING, CONTACTED CHEVY/GM CUSTOMER CARE REGARDING THIS PROBLEM AND EVEN GAVE THEM A TSB THAT I FOUND ON WEBSITE AND INFORMED THEM OF MANY COMPLAINTS FROM OTHER OWNERS. THEY REFUSE TO REPAIR THE FUEL FILTER HOUSING AT THEIR, WHEN I TOOK VEHICLE IN TO BE CHECKED OUT IT STATES THAT THIS NEEDS TO BE REPAIRED AND COULD BE A SAFETY HAZARD AS FUEL CAN LEAK INTO HOUSING AND CATCH FIRE. I TOLD THE CUSTOMER CARE AGENT OF MY CONCERN ABOUT THE SAFETY OF THIS ISSUE AND WAS TOLD THAT GM/CHEVY WOULD NOT PAY FOR IT! I HAVE HAD MAJOR ISSUES WITH THIS VEHICLE FOR OVER SIX MONTHS AND GM REFUSES TO ASSIST ME WITH MOST OF MY CONCERNS.

NHTSA complaint #10448957 — an unverified report by a vehicle owner.

SERVICE BRAKES, HYDRAULIC

SLOWING DOWN TO TURN INTO A SHOPPING CENTER WHEN THE BRAKE PEDAL WENT TO THE FLOOR. I WAS NOT YET COMMITTED TO THE TURN LANE SO I WAS ABLE TO PASS THE ENTRANCE AND STOP ON THE SIDE OF THE ROAD .THIS IS THE SECOND FAILURE THE FIRST ONE OCCURRED LESS THAN 1000 MILES BEFORE ON 5/23/11 ODI #10402905 .THE SERVICE TECH SAYS THE LINE DON'T LOOK THAT BAD ,AND HE COULD NOT BUY REPLACEMENT LINES FROM CHEVROLET. I HAVE BEEN LUCKY TWICE!

NHTSA complaint #10429642 — an unverified report by a vehicle owner.

FUEL SYSTEM, DIESEL

TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 3500. THE CONTACT STATED THAT THE VEHICLE WAS STOPPED WITH THE BRAKES ENGAGED WHEN SHE NOTICED BLACK AND WHITE SMOKE COMING FROM THE MUFFLER. THE FAILURE CONTINUED WHENEVER THE VEHICLE WAS OPERATED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE CONTACT WAS INFORMED THAT THREE OF THE EIGHT INJECTORS FAILED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS UNKNOWN AND THE CURRENT MILEAGE WAS 60,000. UPDATED 07/26/11 *BF THE CONSUMER STATED THREE INJECTORS FAILED. UPDATED 07/28/11

NHTSA complaint #10413270 — an unverified report by a vehicle owner.

SERVICE BRAKES, HYDRAULIC

TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 3500. THE CONTACT WAS DRIVING 70 MPH WHEN HE APPLIED THE BRAKES AND HEARD A LOUD SCRAPING NOISE. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE CONTACT WAS INFORMED THAT ALL FOUR BRAKE PADS AND ROTORS NEEDED TO BE REPLACED. THE BRAKE PADS AND ROTORS WERE REPLACED. THE FAILURE MILEAGE WAS 39,620.

NHTSA complaint #10407092 — an unverified report by a vehicle owner.

SERVICE BRAKES, HYDRAULIC

I WAS UNLOADING MULCH FROM THE BED OF TRUCK ONTO THE FLOWER BEDS IN MY YARD. WHEN I GOT BACK INTO THE TRUCK TO MOVE TO A NEW SPOT EVERYTHING WAS FINE UNTIL I WENT TO STOP AND THE BRAKE PEDAL WENT TO THE FLOOR. THE TRUCK WAS ONLY AT AN IDLE BUT THE BRAKE WOULDN'T EVEN SLOW IT DOWN TO A WALKING SPEED. THE PARKING BRAKE WORKED FINE AND THE TRUCK CAME TO A STOP. I PUT THE REST OF THE MULCHING JOB ON HOLD UNTIL THE NEXT DAY UNTIL I COULD FIGURE OUT WHAT HAD JUST HAPPENED AND HOW TO DEAL WITH IT. THE NEXT DAY I CHECKED THE BRAKE FLUID AND ADDED ALMOST A QUART. WHEN I WENT TO MOVE THE TRUCK THE BRAKE STILL WENT TO THE FLOOR BUT I WAS READY FOR THAT AND GOT THE TRUCK OFF OF THE GRASS AND BACK OUT ONTO THE DRIVEWAY. THAT WAS WHEN I SAW JUST HOW BAD IT WAS LEAKING BRAKE FLUID AND THE TRUCK IS STILL HERE AT MY HOUSE. I GUESS I WILL HAVE IT TOWED SOMEWHERE TO HAVE THE BRAKE LINE THAT RUNS DOWN THE LEFT SIDE OF THE TRUCK TO THE REAR WHEELS REPLACED.

NHTSA complaint #10402905 — an unverified report by a vehicle owner.

SERVICE BRAKES, HYDRAULIC

BRAKE LINES, TRANSMISSION LINES AND ENGINE COOLANT LINES ALL FAILING ON 2004 CHEVY SILVERADO 3500 HD AS WELL AS ON 2003 GMC SIERRA 2500 HD. THESE PROBLEMS HAVE CAUSED NUMEROUS AMOUNTS OF TIME TO REPAIR AND REPLAFE, AND TODAY THERE WAS A BRAKE FAILUER ON THE 2004 HD GMC THAT ALMOST RESULTED IN DEADLY ACCIDENT. THESE LINES SHOULD NOT HAVE RUSTED AND WE HAVE ISSUES WITH BOTH VEHICLES ON THE SAME LINES. THESE VEHICLES WERE PRODUCTED WITH INADEQUATE PARTS FOR ALL LINES ON THE UNDERSIDE OF VEHICLE. THERE SHOULD NOT BE 1,000 PLUS COMPLAINTS FROM CONSUMERS REGARDING THE RUSTING OF THESE COMPONENTS, OF WHICH HAVE CUASED SEVERAL MAJOR ANMD LIFE SAFETY ISSUES. THE BRAKE LINES ARE AN INTEGRAL PART OF ANY VEHICLE AND TO HAVE THEM RUST THRU TO THE DEGREE OF ALL THE COMPLAINTS THERE IS OBVIOUSLY AN ISSUE WITH THE COMPENENTS THE MANUFACTURER INSTALLED ON THESE VEHICLES. BETWEEN OUR 2004 CHEVY AND 2003 GMC TRUCKS WE HAVE REPLACED ALL OF THE TRANMISSION COLLANT LINES, OIL ENGINE LINES AND READY TO CHANGE BRAKE LINES IN 1 TRUCK WITH THE OTHER TRUCK HAVING TO ALSO BE REPLACED DUE TO RUST. THE ENTIRE UNDERSIDE COMPENENTS ARE COMPLETELY RUSTED THROUGH.

NHTSA complaint #10377922 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

BROKEN EXHAUST MANIFOLD BOLTS 2004 6.0 CHEVY SILVERADO 3500 29000 MILES.

NHTSA complaint #10340163 — an unverified report by a vehicle owner.