Model year record

2004 GMC Sierra 2500 recalls & problems

The 2004 GMC Sierra 2500 has 4 safety recalls and 143 owner complaints on file with NHTSA. The most-reported problem area is electrical system (49 complaints).

Recalls4safety recalls

Complaints143filed by owners

Crashes · fires4 · 4reported in complaints

Injuries · deaths5 · 1reported in complaints

Safety recalls

Service brakes, airJun 6, 2006

Service brakes, air

Recall 06E0500006,800 vehicles

Problem: 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.
Risk: IF STOPPING DISTANCE IS LIMITED, A VEHICLE CRASH COULD OCCUR.
Fix: 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.

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).

SteeringFeb 1, 2006

Steering

Recall 06E0100001,360 vehicles

Problem: 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.
Risk: LOSS OF STEERING CONTROL COULD LEAD TO A VEHICLE CRASH WITH POTENTIAL INJURY OR DEATH.
Fix: 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.

Equipment adaptive/mobilityNov 26, 2004

Equipment adaptive/mobility

Recall 04V5620001,660 vehiclesopened after NHTSA action (ODI)

Problem: ON CERTAIN VANS EQUIPPED WITH SURE-LOK WHEELCHAIR SECUREMENT SYSTEMS, THE SPROCKET TEETH OF THE RETRACTOR ASSEMBLY IS OUT OF ALIGNMENT.
Risk: IN THE EVENT OF A VEHICLE CRASH, THE WHEELCHAIR MAY NOT BE ADEQUATELY SECURED POSSIBLY RESULTING IN INJURIES TO A WHEELCHAIR OCCUPANT.
Fix: 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.

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.

What owners report

Problem area	Complaints	Crashes	Fires	Typical mileage*
Electrical systemInstrument cluster/panel; Wiring › Interior/under dash	49	0	3	57,000 mi
Service brakes	33	0	0	95,500 mi
Service brakes, hydraulicAntilock/traction control/electronic limited slip; Power assist	22	1	0	49,500 mi
Power trainAutomatic transmission; Axle assembly › Axle shaft › Seal	10	0	0	73,000 mi
Engine and engine coolingExhaust system; Engine › Diesel	9	0	0	53,000 mi
Engine	9	0	0	50,000 mi
SteeringHydraulic power assist › Pump; Linkages	7	1	0	35,000 mi
Fuel system, diesel	5	0	0	112,000 mi
StructureFrame and members; Frame and members › Underbody shields	5	0	0	54,000 mi
VisibilityRearview mirrors/devices › Exterior; Defroster/defogger/hvac system	3	0	0	54,000 mi
Tires	3	0	0	—
EquipmentAppliance › Air conditioner	2	0	0	—

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

Recent owner complaints

Service brakes
Brakes lines failed under truck do to rusted out lines
Nov 27, 2021
Service brakes
EMERGENCY BRAKES DON'T ENGAGE
Jan 11, 2021
Service brakes
DURING COLD MORNINGS (WISCONSIN) I START MY TRUCK AND I HAVE NO POWER STEERING AND SOFT BRAKES. IT IS MY UNDERSTANDING THAT THE POWER STEERING RUNS THE BRAKE BOOST. ALSO, IT IS MY UNDERSTANDING THAT THERE IS A SERVICE BULLETIN THAT SAYS THAT THE POWER STEERING FLUID SHOULD BE REPLACED WITH LOW/COLD TEMP FLUID. MY CONCERN IS WHAT HAPPENS IF I LOSE POWER STEERING AND BRAKES WHILE I AM DRIVING.
Dec 23, 2019 · 158,500 miles
Engine
WHILE DRIVING OVER 50MPH ON THE HIGHWAY I GET A VIOLENT SHAKING IN THE ENGINE AND THE STEERING WHEEL SHAKES BAKE AND FORTH. THE ENGINE SOUND VERY LOUD WHILE ITS DOING THIS. IT ONLY OCCURS WHEN I AM AT HIGHWAY SPEEDS.
Dec 1, 2018 · 49,000 miles
Engine and engine cooling › Exhaust system › Manifold/header/muffler/tail pipe
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.
Nov 27, 2018 · 90,000 miles
Engine
EXHAUST MANIFOLD BOLTS BROKEN
Aug 28, 2018 · 105,000 miles
Service brakes
PULLING OUT OF A PARKING LOT, LOST BRAKES. STEEL BRAKE LINES BY FUEL TANK, LET GO CAUSING TRUCK TO LOOSE BRAKES
Mar 29, 2018 · 63,000 miles
Electrical system
THE INSTRUMENT PANEL CLUSTER GAUGES DON'T ALWAYS WORK. WE WERE ON FREEWAY WHEN WE NOTICED SPEEDOMETER HAD FAILED AS WELL AS FUEL GAUGE , TEMP GAUGE ALL GAUGES INOPERATIVE. THIS IS THIRD TIME CLUSTER PANEL IS BEING REPLACED; FIRST TWO UNDER WARRANTY THIRD TIME WE HAD TO PAY $204.
Sep 9, 2017 · 111,000 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.