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2004 Chevrolet Silverado 2500

Owner reports · Recalls · Investigations

More warning signs than most Silverado 2500 years

Owner complaints for the 2004 Chevrolet Silverado 2500 are substantially higher than the model-year median of 81.

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When problems were reported

Mileage at the reported incident

336 reports with mileage · 32 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Electrical System. Review the 105 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes. Review the 99 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes, Hydraulic. Review the 68 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

19 crash reports10 fire reports8 injury reports

Engine And Engine Cooling complaints

23 reports
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93,500 miles · Oct 30, 2014
EngineEngine And Engine Cooling

TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO. THE CONTACT STATED THAT THE BOLTS ON THE EXHAUST MANIFOLD WERE FRACTURING. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE TECHNICIAN DIAGNOSED THAT THE MANIFOLD NEEDED TO BE REPLACED. NO REPAIRS WERE MADE TO THE VEHICLE. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE M…

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TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO. THE CONTACT STATED THAT THE BOLTS ON THE EXHAUST MANIFOLD WERE FRACTURING. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE TECHNICIAN DIAGNOSED THAT THE MANIFOLD NEEDED TO BE REPLACED. NO REPAIRS WERE MADE TO THE VEHICLE. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 93,500. UPDATED 12/19/14*CN THE CONSUMER STATED THE MANUFACTURER SHOULD BE RESPONSIBLE FOR THE FAILURE. THERE WAS A CHANCE OF FIRE OR COMPLETE FAILURE CAUSING INJURIES IF THE MANIFOLD BREAKS AWAY FROM THE VEHICLE. UPDATED 05/26/2015 *JS

NHTSA ODI #10651413

Mileage unknown · Sep 25, 2013
Engine And Engine Cooling

EXHAUST MANIFOLD BOLTS BROKE OFF FOR NO REASON, LETTING EXHAUST FUMES ESCAPE UNDER THE HOOD AND IN THE CAB OF THE TRUCK. THIS SEEMS TO BE A VERY COMMON PROBLEM ON SEVERAL GM TRUCKS. *JS

NHTSA ODI #10545389

80,000 miles · Mar 6, 2012
Engine And Engine Cooling

MY TRUCK IS A 2004 CHEVY SILVERADO 2500 WITH 94000 MILES AND THE REAR DRIVER SIDE EXHAUST MANIFOLD BOLT HEAD IS BUSTED OFF. THIS IS NOT THE ONLY CHEVY/GMC 4.8,5.3 OR 6.0 ENGINE THAT HAS THIS PROBLEM. MILLIONS OF OTHERS HAVE THIS SAME PROBLEM AND FROM THIS FAILURE IT CAN LEAD TO FUTURE EMISSION PROBLEMS, CATALYTIC CONVERTER PROBL…

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MY TRUCK IS A 2004 CHEVY SILVERADO 2500 WITH 94000 MILES AND THE REAR DRIVER SIDE EXHAUST MANIFOLD BOLT HEAD IS BUSTED OFF. THIS IS NOT THE ONLY CHEVY/GMC 4.8,5.3 OR 6.0 ENGINE THAT HAS THIS PROBLEM. MILLIONS OF OTHERS HAVE THIS SAME PROBLEM AND FROM THIS FAILURE IT CAN LEAD TO FUTURE EMISSION PROBLEMS, CATALYTIC CONVERTER PROBLEMS, EXHAUST LEAK IN THE ENGINE COMPARTMENT LEADING TO EXHAUST FUMES BEING LEAKED INTO THE CAB OF THE VEHICLE WHICH WOULD BE CARBON MONOXIDE POISONING. THIS IS A MAJOR ISSUE THAT GM SHOULD TAKE CARE OF AS A RECALL !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! *TR

NHTSA ODI #10450569

100,950 miles · Feb 27, 2012
Engine And Engine Cooling

FOUR EXHAUST MANIFOLD BOLTS HAVE BROKEN OFF SINCE I'VE OWNED THIS TRUCK AND THE MANIFOLD HAS CRACKED. IT IS A DESIGN FLAW THAT OCCURS IN MANY OF THE SIMILAR V8 EQUIPPED MODELS AND HAS BEEN WELL DOCUMENTED ON THE INTERNET. THIS SHOULD BE RECALLED BY GM. THIS PROBLEM ALSO LEADS TO FAULTY EMISSION READINGS BY THE VEHICLE AND THE…

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FOUR EXHAUST MANIFOLD BOLTS HAVE BROKEN OFF SINCE I'VE OWNED THIS TRUCK AND THE MANIFOLD HAS CRACKED. IT IS A DESIGN FLAW THAT OCCURS IN MANY OF THE SIMILAR V8 EQUIPPED MODELS AND HAS BEEN WELL DOCUMENTED ON THE INTERNET. THIS SHOULD BE RECALLED BY GM. THIS PROBLEM ALSO LEADS TO FAULTY EMISSION READINGS BY THE VEHICLE AND THE CHECK ENGINE LIGHT WILL GO ON AND REMAIN ON UNTIL THIS EXPENSIVE PROBLEM IS FIXED. *TR

NHTSA ODI #10449502

55,000 miles · Sep 9, 2011
Engine And Engine CoolingFire

TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500 HD. THE CONTACT STATED THAT WHILE TOWING A TRAILER AT APPROXIMATELY 55 MPH, A CLICKING NOISE WAS HEARD FROM THE ENGINE AND THE ENGINE EXPLODED. THE CONTACT ALSO OBSERVED SMOKE RISING FROM THE ENGINE DURING THE FAILURE. THE VEHICLE WAS TOWED TO AN INDEPENDENT REPAIR SHOP WHERE …

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TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500 HD. THE CONTACT STATED THAT WHILE TOWING A TRAILER AT APPROXIMATELY 55 MPH, A CLICKING NOISE WAS HEARD FROM THE ENGINE AND THE ENGINE EXPLODED. THE CONTACT ALSO OBSERVED SMOKE RISING FROM THE ENGINE DURING THE FAILURE. THE VEHICLE WAS TOWED TO AN INDEPENDENT REPAIR SHOP WHERE THE CONTACT WAS INFORMED THAT THE ENGINE EXPLODED AND ALL OF ITS COMPONENTS WERE MELTED. THE VEHICLE WAS THEN TOWED TO AN AUTHORIZED DEALER WHERE THE FAILURE WAS CONFIRMED AND THE CONTACT WAS ADVISED THAT THE ENGINE WAS DESTROYED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE, BUT OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS 55,000.

NHTSA ODI #10424494

32,533 miles · Aug 9, 2011
Engine And Engine Cooling

I HAVE A 2004 SILVERADO K2500 WITH A DURAMAX DIESEL (LLY). I BOUGHT THIS TRUCK NEW IN SEPTEMBER 2004. I PULL A FIFTH WHEEL CAMPER. MY TRUCK HAS OVERHEATED MORE THAN TWO DOZEN TIMES, AND ON SOME OCCASIONS LOST POWER, WHILE PULLING THE CAMPER UP LONG GRADES. I REPORTED THIS PROBLEM TWICE TO CHEVROLET DEALERS. I HAVE THE SERVI…

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I HAVE A 2004 SILVERADO K2500 WITH A DURAMAX DIESEL (LLY). I BOUGHT THIS TRUCK NEW IN SEPTEMBER 2004. I PULL A FIFTH WHEEL CAMPER. MY TRUCK HAS OVERHEATED MORE THAN TWO DOZEN TIMES, AND ON SOME OCCASIONS LOST POWER, WHILE PULLING THE CAMPER UP LONG GRADES. I REPORTED THIS PROBLEM TWICE TO CHEVROLET DEALERS. I HAVE THE SERVICE ORDERS THAT CLEARLY DESCRIBE MY OVERHEATING PROBLEM. BOTH OF THESE SERVICE CALLS WERE WHILE THE TRUCK WAS UNDER WARRANTY, BUT THE DEALERS COULD NOT FIX THE PROBLEM. LATER WHEN THE TRUCK WAS OUT OF WARRANTY, I FOUND OUT THAT GENERAL MOTORS RECOGNIZED THE OVERHEATING PROBLEM AND ISSUED A SERVICE BULLETIN #06-06-04-036D THAT DESCRIBES MY HEATING PROBLEM EXACTLY. THIS SERVICE BULLETIN WAS ISSUED PRIOR TO EITHER OF MY COMPLAINTS ABOUT OVERHEATING. THE COST OF IMPLEMENTING SERVICE BULLETIN #06-06-04-036D IS APPROXIMATELY $1,300 DOLLARS, SO GENERAL MOTORS RECOGNIZES THAT THIS SERIES TRUCK HAS A SIGNIFICANT OVERHEATING PROBLEM, BUT APPARENTLY THEY ARE HIDING THIS FIX FROM THE OWNERS UNTIL THE VEHICLE IS OUT OF WARRANTY. I CAN GIVE MANY INSTANCES WHERE THIS OVERHEATING PROBLEM HAS CAUSED A SAFETY PROBLEM. ONE TIME I WAS PULLING THE CAMPER EAST ON INTERSTATE 40 ABOUT A 150 MILES WEST OF ALBUQUERQUE, NM WHEN THE TRUCK OVERHEATED AND LOST POWER. THERE WAS NO GOOD PLACE TO PULL OVER AND I WAS TERRIFIED AS THE HEAVY TRAFFIC HAD TO CHANGE LANES AND PASS ME. ANOTHER TIME I WAS PULLING UP TO THE NORTH RIM OF THE GRAND CANYON ON A TWO LANE ROAD WHEN THE TRUCK OVERHEATED, LOST POWER AND I HAD A LONG LINE OF TRAFFIC BEHIND ME. IT WAS DANGEROUS AS THE TRAFFIC PASSED ME WITHOUT GOOD CLEARANCE. I COULD GO ON AND ON OF SIMILAR SITUATIONS THAT CAUSED DANGEROUS CONDITIONS. THERE IS ALSO A WEBSITE AT WWW.DIESELPLACE.COM THAT HAS AN ENTIRE SECTION DEVOTED TO THE LLY DIESEL. THERE ARE OVER A THOUSAND POSTS CONCERNING THIS OVERHEATING PROBLEM. *TR

NHTSA ODI #10418172

59,000 miles · Aug 1, 2011
Engine And Engine Cooling

AIR COND. COMPRESSOR FAILED, SEIZED!. *KB

NHTSA ODI #10416435

77,000 miles · Jul 26, 2011
Electrical SystemEngine And Engine Cooling

2004 CHEVROLET SILVERADO 2500HD. CONSUMER STATES GAUGES STOPPED WORKING AND THE BOLTS ON THE MANIFOLD WERE DEFECTIVE. *TGW

NHTSA ODI #10415868

124,864 miles · Jul 25, 2011
Engine And Engine Cooling

TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500 HD DIESEL. THE CONTACT STATED WHILE DRIVING, THE CHECK ENGINE LIGHT ILLUMINATED AND THE VEHICLE STALLED. THE CONTACT MENTIONED THE FAILURE HAPPENED SEVERAL TIMES. THE VEHICLE WAS TAKEN TO THE DEALER WHO WAS UNABLE TO DIAGNOSE THE FAILURE. THE MANUFACTURER WAS MADE AWARE OF THE…

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TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500 HD DIESEL. THE CONTACT STATED WHILE DRIVING, THE CHECK ENGINE LIGHT ILLUMINATED AND THE VEHICLE STALLED. THE CONTACT MENTIONED THE FAILURE HAPPENED SEVERAL TIMES. THE VEHICLE WAS TAKEN TO THE DEALER WHO WAS UNABLE TO DIAGNOSE THE FAILURE. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE BUT STATED THEY WOULD CONTACT HIM AT A LATER DATE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS UNKNOWN AND THE CURRENT MILEAGE WAS 124,869.

NHTSA ODI #10414999

85,000 miles · Jun 21, 2011
Engine And Engine Cooling

I OWN A 2004 CHEVROLET SILVERADO 2500. IT HAS A BROKEN EXHAUST MANIFOLD BOLT. AFTER RESEARCHING THIS PROBLEM ON THE INTERNET, I FOUND THERE ARE APPROXIMATELY 12,000,000 GM VEHICLES WITH THIS PROBLEM. WHY HASN'T THE NHTSA ISSUED A RECALL ON THESE VEHICLES? IT SEEMS TO ME THAT THE EPA WOULD HAVE DONE SOMETHING ABOUT AS THE BR…

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I OWN A 2004 CHEVROLET SILVERADO 2500. IT HAS A BROKEN EXHAUST MANIFOLD BOLT. AFTER RESEARCHING THIS PROBLEM ON THE INTERNET, I FOUND THERE ARE APPROXIMATELY 12,000,000 GM VEHICLES WITH THIS PROBLEM. WHY HASN'T THE NHTSA ISSUED A RECALL ON THESE VEHICLES? IT SEEMS TO ME THAT THE EPA WOULD HAVE DONE SOMETHING ABOUT AS THE BROKEN BOLT IS ALLOWING EXHAUST INTO THE AIR WITHOUT GOING THROUGH THE CONVERTER. I DON'T KNOW AT WHAT MILEAGE THE BOLT BROKE OR AT WHAT SPEED I WAS GOING WHEN IT HAPPENED. *TR

NHTSA ODI #10407762

Official recalls

0

No recalls in this snapshot.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

0

No exact-year investigations in this snapshot.