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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

Service Brakes, Hydraulic complaints

68 reports
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59,600 miles · Oct 17, 2011
Service Brakes, Hydraulic

WAS TESTING THE BRAKES ON A BOAT TRAILER BEFORE TOWING IT AWAY AND A STEEL BRAKE LINE RUNNING INSIDE THE FRAME CHANNEL BEHIND THE DRIVER'S SIDE REAR WHEEL SUDDENLY BURST. UPON INSPECTION, THE LINE WAS COMPLETELY ROTTEN FOR ABOUT A 3 TO 4 INCH SECTION IN THAT AREA. NO WARNING, ANOTHER 10 MINUTES I WOULD HAVE BEEN TOWING A HEAVY T…

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WAS TESTING THE BRAKES ON A BOAT TRAILER BEFORE TOWING IT AWAY AND A STEEL BRAKE LINE RUNNING INSIDE THE FRAME CHANNEL BEHIND THE DRIVER'S SIDE REAR WHEEL SUDDENLY BURST. UPON INSPECTION, THE LINE WAS COMPLETELY ROTTEN FOR ABOUT A 3 TO 4 INCH SECTION IN THAT AREA. NO WARNING, ANOTHER 10 MINUTES I WOULD HAVE BEEN TOWING A HEAVY TRAILER AND THE BRAKES WOULD HAVE FAILED AT ANY SUDDEN STOP. AFTER THIS LINE FAILURE, THE TRUCK HAS NO BRAKES EXCEPT THE E-BRAKE, WHICH ISN'T MUCH. HOPEFULLY THERE WILL BE A RECALL, THOUGH I ALREADY DROPPED $600 AT THE SHOP TO GET IT FIXED TODAY. *TR

NHTSA ODI #10430551

91,000 miles · Sep 14, 2011
Service Brakes, Hydraulic

TOTAL BRAKE FAILURE IN MY DRIVEWAY. BRAKE LINES RUSTED THROUGH. *KB

NHTSA ODI #10425408

70,249 miles · Aug 3, 2011
Parking BrakeService Brakes, Hydraulic

2004 SILVERADO 2500 HD, WHILE TOWING APPROX. 7000LBS MY BRAKE LINE RUPTURED, LUCKILY I HAD THE TRAILER BRAKES TO STOP ME BECAUSE THE PEDAL WENT STRAIGHT TO THE FLOOR. UPON INSPECTING CLOSELY THE BRAKE LINES ARE SO RUSTED YOU CAN LITERALLY SMASH THEM BETWEEN YOUR FINGERS. THIS IS THE NEWEST VEHICLE I OWN AND IS IN THE WORST SHAPE…

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2004 SILVERADO 2500 HD, WHILE TOWING APPROX. 7000LBS MY BRAKE LINE RUPTURED, LUCKILY I HAD THE TRAILER BRAKES TO STOP ME BECAUSE THE PEDAL WENT STRAIGHT TO THE FLOOR. UPON INSPECTING CLOSELY THE BRAKE LINES ARE SO RUSTED YOU CAN LITERALLY SMASH THEM BETWEEN YOUR FINGERS. THIS IS THE NEWEST VEHICLE I OWN AND IS IN THE WORST SHAPE AS FAR AS CORROSION GOES, A SHAME AT 70K MILES. TRUCK IS IN THE SHOP NOW, CAN ONLY IMAGINE WHAT THIS WILL COST. ALREADY REPLACED ROTORS DUE TO CORROSION, E-BRAKE CABLES, WHEEL SPEED SENSOR(BRACKET ROTTED OFF). *KB

NHTSA ODI #10416829

47,212 miles · Jul 24, 2011
Fuel System, GasolineService Brakes, Hydraulic

I WAS BACKING TRUCK INTO DRIVE WAY MOVING ABOUT 5MPH AND APPLIED BRAKES TO PUT TRUCK INTO REVERSE AND BRAKE PEDAL WENT TO FLOOR DID NOT STOP TRUCK. STEEL BRAKE LINE RUPTURED WHERE THE ABS MODULE IS UNDER THE TRUCK RIGHT BELOW DRIVER SEAT. ALL BRAKE LINES LOOK EXTREMELY RUSTY. TRUCK IS A 2004 2500HD CREW CAB 4X4. I BOUGHT BRAND …

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I WAS BACKING TRUCK INTO DRIVE WAY MOVING ABOUT 5MPH AND APPLIED BRAKES TO PUT TRUCK INTO REVERSE AND BRAKE PEDAL WENT TO FLOOR DID NOT STOP TRUCK. STEEL BRAKE LINE RUPTURED WHERE THE ABS MODULE IS UNDER THE TRUCK RIGHT BELOW DRIVER SEAT. ALL BRAKE LINES LOOK EXTREMELY RUSTY. TRUCK IS A 2004 2500HD CREW CAB 4X4. I BOUGHT BRAND NEW AND IT HAS 47,212 MILES. I PULL A 7000 LBS. CAMPER AND I'M GLAD IT HAPPENED IN MY DRIVEWAY. IN JUNE THE RUBBER GAS LINE FAILED PUMPING 15 GALLONS OF GAS ONTO BOTTOM OF TRUCK AND GROUND ON THE WAY TO WORK (27 MILES). ONCE AGAIN, I WAS LUCKY. I PREFER TO NOT HAVE ANY OTHER STRIKES, TWO IS ENOUGH FOR ME! I HOPE IT DOES NOT TAKE AN INJURY, DEATH, ACCIDENT OR PROPERTY DAMAGE TO GET THE NEEDED ATTENTION THIS VEHICLE NEEDS. *TR

NHTSA ODI #10414895

63,491 miles · Jul 24, 2011
Service Brakes, Hydraulic

I OWN A 2004 SILVERADO 2500HD CREW CAB. I WAS LEAVING A LAKE BOAT RAMP WITH MY BOAT IN TOW WHEN, WITHOUT WARNING, THE BRAKE PEDAL WENT TO THE FLOOR. WITH THE ASSISTANCE OF THE E-BRAKE I WAS ABLE TO BRING IT TO A STOP ON THE SHOULDER. AFTER INSPECTING UNDER THE HOOD I WENT UNDER THE TRUCK AND FOUND THAT THE BRAKE LINES INTO THE …

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I OWN A 2004 SILVERADO 2500HD CREW CAB. I WAS LEAVING A LAKE BOAT RAMP WITH MY BOAT IN TOW WHEN, WITHOUT WARNING, THE BRAKE PEDAL WENT TO THE FLOOR. WITH THE ASSISTANCE OF THE E-BRAKE I WAS ABLE TO BRING IT TO A STOP ON THE SHOULDER. AFTER INSPECTING UNDER THE HOOD I WENT UNDER THE TRUCK AND FOUND THAT THE BRAKE LINES INTO THE PROPORTIONING VALVE WERE SEVERELY RUSTED AND ONE HAD RUPTURED. I HAD TO HAVE THE VEHICLE TOWED AT THIS POINT. UPON RETURNING HOME I BEGAN LOOKING FOR REPLACEMENT PARTS AND FOUND THAT YOUR AGENCY IS INVESTIGATING THIS PROBLEM. I FIND IT UNSATISFACTORY THAT THERE HASN'T BEEN AT LEAST AN ADVISORY TO AT LEAST INSPECT SO AT LEAST THE OWNERS OF THESE VEHICLES WOULD HAVE A CHANCE TO PROTECT THEMSELVES, THEIR PROPERTY, AND OTHER INDIVIDUALS FROM HARM. THANK GOODNESS I WAS NOT GOING ANY FASTER THAN I WAS. THERE WAS NO WARNING AND I HAD MY FAMILY WITH ME. WOULD YOU PLEASE AT LEAST PUT SOMETHING OUT. I KNOW THERE IS CURRENTLY NO RECALL. HOW CAN THIS BE??? THERE IS NOTHING MORE DANGEROUS THAN A 9000LB+ TRUCK WITH NO BRAKES!! HOW LONG DO YOU PLAN ON "RESEARCHING" THIS? I AM AN AIRCRAFT MECHANIC AND KNOW THAT SAFETY CHANGES ARE USUALLY WRITTEN IN BLOOD!! PLEASE STOP ACTING LIKE THE FAA AND BE PROACTIVE ON THIS ISSUE. UPDATED 08/11/11 *BF *TR UPDATED 06/06/12* JS

NHTSA ODI #10414892

157,400 miles · Jul 21, 2011
Service Brakes, Hydraulic

I WAS ON A STATE ROAD DOING 50 MPH LEAVING MY TOWN AND WENT TO TURN AND MY BRAKE PEDAL WENT TO THE FLOOR. I WAS ABLE TO SLOW DOWN AND PULL OVER AND NOT GET IN AN ACCIDENT. I WAS ABLE TO GET HOME AND DISCOVERED NO BRAKE FLUID. I FILLED UP THE FLUID AND STARTED TO BLEED THE BRAKE. THAT'S WHEN I NOTICED THE RUSTED OUT BRAKE LIN…

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I WAS ON A STATE ROAD DOING 50 MPH LEAVING MY TOWN AND WENT TO TURN AND MY BRAKE PEDAL WENT TO THE FLOOR. I WAS ABLE TO SLOW DOWN AND PULL OVER AND NOT GET IN AN ACCIDENT. I WAS ABLE TO GET HOME AND DISCOVERED NO BRAKE FLUID. I FILLED UP THE FLUID AND STARTED TO BLEED THE BRAKE. THAT'S WHEN I NOTICED THE RUSTED OUT BRAKE LINES AND THE BRAKE FLUID SPRAYING OUT. I HAVE ORDERED NEW BRAKE LINE FROM INLINE TUBE. I WAS LUCKY TO NOT CRASH BUT I AM WORRIED ABOUT OTHERS WHO MAY HAVE THIS PROBLEM AND NOT BE AS LUCKY AS ME. *KB

NHTSA ODI #10413887

39,000 miles · Jul 19, 2011
Service Brakes, Hydraulic

TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500. THE CONTACT STATED THAT WHILE REVERSING FROM A DRIVEWAY, THE BRAKES WERE APPLIED AND THE PEDAL DEPRESSED TO THE FLOOR. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC, WHO STATED THAT THE BRAKE LINES WERE CORRODED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE …

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TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500. THE CONTACT STATED THAT WHILE REVERSING FROM A DRIVEWAY, THE BRAKES WERE APPLIED AND THE PEDAL DEPRESSED TO THE FLOOR. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC, WHO STATED THAT THE BRAKE LINES WERE CORRODED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE AND CURRENT MILEAGES WERE APPROXIMATELY 39,000.

NHTSA ODI #10413554

67,606 miles · Jun 13, 2011
Service Brakes, HydraulicCrash

BRAKE LINE BURST AND WE LOST OUR BRAKES! SLOW SPEED AND RURAL LOCATION SO WE WERE ABLE TO STOP BY STEERING OFF-ROAD AND INTO SOME BUSHES. INSPECTED THE BRAKE LINES AND FOUND A LEAK IN THE STEEL LINE GOING TO THE LEFT FRONT BRAKE. THE BRAKE LINE HAD EXTENSIVE CORROSION ON IT AS WELL AS CORROSION ON ADJACENT LINES. THIS IS NOT …

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BRAKE LINE BURST AND WE LOST OUR BRAKES! SLOW SPEED AND RURAL LOCATION SO WE WERE ABLE TO STOP BY STEERING OFF-ROAD AND INTO SOME BUSHES. INSPECTED THE BRAKE LINES AND FOUND A LEAK IN THE STEEL LINE GOING TO THE LEFT FRONT BRAKE. THE BRAKE LINE HAD EXTENSIVE CORROSION ON IT AS WELL AS CORROSION ON ADJACENT LINES. THIS IS NOT A MAINTENANCE ISSUE, STEEL BRAKE LINES IN THIS PART OF THE COUNTRY DO NOT RUST OUT AT 67,606 MILES... EXCEPT ON THIS TRUCK. SHAMEFUL DESIGN AND POOR MATERIALS ARE THE CAUSE. SOMEBODY COULD HAVE BEEN INJURED OR KILLED!

NHTSA ODI #10406668

110,000 miles · Jun 2, 2011
Service Brakes, Hydraulic

2004 CHEVROLET 2500 CREW CAB TRUCK BRAKE LINES COMPLETELY RUSTED OUT. NOTICED PROBLEMS WITH BRAKES NOT WEARING EVENLY AND EVENTUAL LOSS OF BRAKING. TOOK TRUCK TO ORIGINAL DEALER FOR SERVICING TO FIND OUT THE BRAKE LINES WERE COMPLETELY RUSTED AND FLUID LEAKING FROM THE RUSTED AREAS. WAS INFORMED BY THE DEALER THAT IT WAS NOT …

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2004 CHEVROLET 2500 CREW CAB TRUCK BRAKE LINES COMPLETELY RUSTED OUT. NOTICED PROBLEMS WITH BRAKES NOT WEARING EVENLY AND EVENTUAL LOSS OF BRAKING. TOOK TRUCK TO ORIGINAL DEALER FOR SERVICING TO FIND OUT THE BRAKE LINES WERE COMPLETELY RUSTED AND FLUID LEAKING FROM THE RUSTED AREAS. WAS INFORMED BY THE DEALER THAT IT WAS NOT COST EFFECTIVE TO REPLACE ALL THE BRAKE LINES BECAUSE THEY WOULD HAVE TO BE CUSTOM FIT. WE ALSO HAVE A 2000 CHEVROLET 1500 EXTENDED CAB THAT HAS DOUBLE THE MILEAGE OF THE 2004 AND IS STILL WORKING PERFECTLY, NO RUSTED LINES. *TR

NHTSA ODI #10404178

89,000 miles · May 15, 2011
Service Brakes, Hydraulic

NO ACCIDENT YET - WHEEL IS RUBBING BRAKE HOSE. FACTORY WHEEL, FACTORY BRAKE HOSE. NO AFTERMARKET PARTS INVOLVED. LEFT FRONT RUBBER BRAKE HOSE. *TR

NHTSA ODI #10400916

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.