Model year record

2004 Chevrolet Tahoe recalls & problems

The 2004 Chevrolet Tahoe has 5 safety recalls and 467 owner complaints on file with NHTSA. The most-reported problem area is electrical system (215 complaints).

Recalls5safety recalls

Complaints467filed by owners

Crashes · fires25 · 7reported in complaints

Injuries · deaths24 · 1reported in complaints

Safety recalls

WheelsDec 17, 2007

Hub

Recall 07E106000130,000 vehicles

Problem: CERTAIN FEDERAL-MOGUL REPLACEMENT WHEEL HUB ASSEMBLIES WITH THE BRAND NAMES: NATIONAL, CARQUEST P/NOS. 515020, 515021, 515025, 515053, 515054, 515059, AND 515060, SHIPPED BETWEEN JANUARY 23, 2006, AND DECEMBER 20, 2007, SOLD FOR LIGHT DUTY AND MEDIUM DUTY TRUCKS. THE INBOARD RETENTION NUT USED TO MAINTAIN HUB BEARING ASSEMBLY CAN LOOSEN RESULTING IN AN ABS LIGHT INDICATION, NOISE, AND/OR WHEEL SEPARATION.
Risk: WHEEL SEPARATION CAN RESULT IN A VEHICLE CRASH.
Fix: FEDERAL-MOGUL WILL NOTIFY CUSTOMERS AND WILL REPLACE THE HUB ASSEMBLY FREE OF CHARGE. THE RECALL BEGAN ON FEBRUARY 7, 2008. OWNERS CAN CONTACT FEDERAL-MOGUL TOLL-FREE AT 877-489-6659.

Fuel system, gasolineMay 19, 2006

Fuel system, gasoline

Recall 06E04300088,303 vehicles

Problem: 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.
Risk: 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.
Fix: 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).

Exterior lightingMar 23, 2006

Exterior lighting

Recall 06E02600061,944 vehiclesopened after NHTSA action (OVSC)

Problem: CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
Risk: WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.
Fix: PRO-A MOTORS WILL NOTIFY OWNERS AND OFFER TO REPURCHASE THE LAMPS. THE RECALL BEGAN ON APRIL 3, 2006. OWNERS MAY CONTACT PRO-A MOTORS AT 323-838-2988.

Seat beltsApr 22, 2005

Rear/other

Recall 05V1630001,359,824 vehicles

Problem: ON CERTAIN CREW CAB PICKUP TRUCKS AND SPORT UTILITY VEHICLES, THE 2ND ROW CENTER OCCUPANT SEAT BELT ROUTING MAY MAKE IT DIFFICULT TO POSITION THE LAP PORTION OF THE SAFETY BELT LOW AROUND THE HIPS OF OCCUPANTS, ESPECIALLY SMALLER OCCUPANTS, SEATED IN THIS POSITION. APPROPRIATE USE OF A CHILD SEAT OR BOOSTER SEAT, AS RECOMMENDED FOR SMALL CHILDREN, DOES IMPROVE THE FIT CONDITION FOR THIS USER GROUP. IN ADDITION TO INSTRUCTIONS ON PROPER INFANT AND YOUNG CHILD RESTRAINT (WITH CHILD SEATS OR BOOSTERS), SPECIAL VERBIAGE FOR RESTRAINING OLDER CHILD IS INCLUDED IN THE OWNER'S MANUAL. ALSO, THE SUGGESTED SEAT BELT FIT/ROUTING FOR ADULTS, IRRESPECTIVE OF SEATING POSITION, IS DESCRIBED IN THE OWNER'S MANUAL TEXT.
Risk: A LAP PORTION OF THE SEAT BELT ROUTING THAT IS NOT LOW AND SNUG ON THE HIPS CAN ALLOW THE LAP BELT TO RIDE UP ON AN OCCUPANT'S ABDOMEN INSTEAD OF FITTING LOW AROUND THEIR HIPBONES, AND THEREFORE, CAN EXPOSE THEM TO MORE RISK OF ABDOMINAL AND INTERNAL ORGAN INJURY.
Fix: DEALERS WILL CUT OPEN THE GUIDE LOOP, REMOVE A PORTION OF THE LOOP, AND THEN THE REMAINING TWO SIDES SHOULD BE FOLDED OVER AND SECURED WITH A RETAINER FREE OF CHARGE. THE RECALL BEGAN ON JULY 21, 2005. OWNERS MAY CONTACT CADILLAC AT 1-866-982-2339, CHEVROLET AT 1-800-630-2438, GMC AT 1-866-996-9463, OR HUMMER AT 1-800-732-5493.

Service brakes, hydraulicFeb 4, 2004

Service brakes, hydraulic

Recall 04V04500068,875 vehicles

Problem: CERTAIN SPORT UTILITY VEHICLES, PICKUP TRUCKS, AND PASSENGER VANS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 135, ?PASSENGER CAR BRAKE SYSTEMS.? SOME OF THESE VEHICLES WERE PRODUCED WITH AN OUT-OF-SPECIFICATION BRAKE HYDRO-BOOST HOUSING RELIEF VALVE BORE.
Risk: CONSEQUENTLY, THE VALVE O-RING SEAL MAY FRACTURE. STEERING EFFORTS MAY BE SLIGHTLY INCREASED WHILE BRAKING OR PARKING. UNDER CERTAIN DRIVING CONDITIONS, A FRACTURED SEAL MAY REQUIRE A SLIGHT INCREASE IN THE APPLIED BRAKE PEDAL EFFORT TO ACHIEVE THE SAME VEHICLE DECELERATION RATE AS PRIOR TO THE SEAT FRACTURE.
Fix: DEALERS ARE TO REPLACE THE HYDRO-BOOST RELIEF VALVE. THE RECALL BEGAN ON JUNE 18, 2004. OWNERS SHOULD CONTACT CADILLAC AT 1-866-982-2339; CHEVROLET AT 1-800-630-2438; GMC AT 1-866-996-9463; OR HUMMER AT 1-866-486-6376.

Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.

Crash test ratings

2004 Chevrolet Tahoe 4-DR. w/SAB

OverallNot Rated

Frontal crash	Not Rated
Side crash	Not Rated
Rollover	★★★★★
Rollover risk	26.3%

NHTSA 5-Star Safety Ratings (New Car Assessment Program). Ratings are comparable only between vehicles of similar size and weight, and ratings from 2011 on use tougher tests than earlier years. Photos: NHTSA.

Fuel economy

Tahoe 1500 2WD

15mpg combined

City / highway	14 / 18 mpg
Fuel	Regular Gasoline

4.8 L · 8 cyl · Automatic 4-spd · Rear-Wheel Drive · about $4,450/year to fuel

Tahoe 1500 4WD

15mpg combined

City / highway	13 / 17 mpg
Fuel	Regular Gasoline

4.8 L · 8 cyl · Automatic 4-spd · 4-Wheel or All-Wheel Drive · about $4,450/year to fuel

Tahoe 1500 2WD FFV

15mpg combined

City / highway	13 / 17 mpg
Fuel	Regular Gasoline

5.3 L · 8 cyl · Automatic 4-spd · Rear-Wheel Drive · about $4,450/year to fuel

Tahoe 1500 2WD

14mpg combined

City / highway	13 / 17 mpg
Fuel	Regular Gasoline

5.3 L · 8 cyl · Automatic 4-spd · Rear-Wheel Drive · about $4,800/year to fuel

Tahoe 1500 4WD

14mpg combined

City / highway	13 / 17 mpg
Fuel	Regular Gasoline

5.3 L · 8 cyl · Automatic 4-spd · 4-Wheel or All-Wheel Drive · about $4,800/year to fuel

Tahoe 1500 AWD

14mpg combined

City / highway	13 / 17 mpg
Fuel	Regular Gasoline

5.3 L · 8 cyl · Automatic 4-spd · 4-Wheel or All-Wheel Drive · about $4,800/year to fuel

Tahoe 1500 4WD FFV

14mpg combined

City / highway	13 / 17 mpg
Fuel	Regular Gasoline

5.3 L · 8 cyl · Automatic 4-spd · 4-Wheel or All-Wheel Drive · about $4,800/year to fuel

Tahoe 1500 AWD FFV

14mpg combined

City / highway	13 / 17 mpg
Fuel	Regular Gasoline

5.3 L · 8 cyl · Automatic 4-spd · 4-Wheel or All-Wheel Drive · about $4,800/year to fuel

EPA estimates from fueleconomy.gov for each engine and transmission sold. Annual cost is the EPA's estimate for 15,000 miles a year at its current fuel and electricity price assumptions. Your results will vary.

What owners report

Problem area	Complaints	Crashes	Fires	Injuries	Typical mileage*
Electrical systemInstrument cluster/panel; 12v/24v/48v battery	215	1	3	0	68,000 mi
Service brakes	60	10	1	3	112,000 mi
SteeringColumn; Hydraulic power assist › Hose, piping, and connections	29	1	0	0	52,000 mi
Vehicle speed controlAccelerator pedal; Cables	27	1	0	2	53,974 mi
Power trainAutomatic transmission; Automatic transmission › Lever and linkage › Column shift	26	2	0	1	37,849 mi
Engine	26	1	2	0	115,000 mi
Service brakes, hydraulicFoundation components › Hoses, lines/piping, and fittings; Antilock/traction control/electronic limited slip	25	1	0	0	55,000 mi
Engine and engine coolingEngine; Exhaust system	22	0	1	0	41,000 mi
StructureBody › Hatchback/liftgate › Hinge and attachments; Body › Tailgate › Hinge and attachments	15	0	0	0	66,500 mi
Air bagsFrontal; Side/window	15	9	0	15	74,000 mi
VisibilityDefroster/defogger/hvac system › Fan/motor; Defroster/defogger/hvac system	11	0	1	0	62,500 mi
SeatsFront assembly › Power adjust; Front assembly › Seat heater/cooler	10	1	0	1	72,000 mi

*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.

Recent owner complaints

Steering
My brakes locked up with steering wheel and cause me to go off the road itâs very unsafe and there should be recall immediately
Sep 1, 2026
Seat belts
UNKNOWN
Apr 22, 2005
Power train
My Tahoe has the New Process 246GM transfer case. They have a known issue called pump rub where the pump is to close to the magnesium shell, and rubs pin holes in the shell which causes fluid to dissipate over time causing the transfer case to run dry burning it up. I've had a mechanic check it out and there was no fluid in the case, and now I have a transfer case that's burned up. I've called a transmission shop, and they told me it was a common issue. I would like for general motors to correct this issue
Jul 15, 2023
Service brakes, hydraulic
The contact's spouse owns a 2004 Chevrolet Tahoe. The contact stated while driving approximately 35 MPH, the brake pedal was depressed and remained extended to the floorboard. The contact engaged the parking brake to bring the vehicle to a complete stop. The vehicle was driven to the residence and parked. Additionally, the contact stated that while parked, the brake pedal was depressed, and brake fluid was squirting onto the ground from underneath the front of the vehicle. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The failure mileage was 190,000.
Mar 23, 2023 · 190,000 miles
Service brakes, hydraulic
The contact owns a 2004 Chevrolet Tahoe. The contact stated that while driving at an undisclosed speed, the brakes failed to stop the vehicle immediately while the brake pedal was being depressed. The vehicle was taken to the dealer where it was diagnosed that the failure was related to NHTSA Campaign Number: 04V045000 (Service Brakes, Hydraulic) however, the VIN was not included in the recall. The vehicle was not repaired. The manufacturer was made aware of the failure and advised the contact to file a complaint with the NHTSA Hotline. The failure mileage was approximately 150,000.
Sep 2, 2022 · 150,000 miles
Service brakes, hydraulic
The contact owns a 2004 Chevrolet Tahoe. The contact stated that while inspecting the coils under the hood, he noticed that the master cylinder brake lines were leaking. The vehicle was taken to an independent mechanic who diagnosed that the master cylinder brake lines needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 183,500. The VIN was unavailable.
Mar 28, 2022 · 183,500 miles
Engine
MY2004 CHEVY TAHOE LT WAS MOVING WHEN THE REAR VIEW MIRROR FELL OFF THE WINDSHIELD. ALSO THE EXHAUST MANIFOLD BOLTS HAVE BROKEN OFF WHICH CAUSE BAD GAS MILEAGE AND SLOW TAKE OFFS.
Jul 28, 2020 · 210,000 miles
Service brakes
THIS IS IN REFERENCE TO COMPLAINT # 11327456 THE ADDRESS AND THE MPH ARE INCORRECT. PLEASE SEE FORM ATTACHED TO THIS COMPLAINT # AFFECTED PARTS: STEERING, BRAKES, ELECTRICAL, ELEC, STABILITY CONTROL AND SPEED CONTROL THIS SITE WOULDN'T LET ME CHECK MORE THAN 3. *TR
Aug 19, 2019 · 230,000 miles

Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.