← New search

2004 GMC Sierra 2500

Owner reports · Recalls · Investigations

More warning signs than most Sierra 2500 years

Owner complaints for the 2004 GMC Sierra 2500 are substantially higher than the model-year median of 46.

About this comparison →

When problems were reported

Mileage at the reported incident

122 reports with mileage · 21 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 48 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes. Review the 33 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes, Hydraulic. Review the 22 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

4 crash reports4 fire reports3 injury reports

Service Brakes complaints

33 reports
Clear category filter
75,000 miles · Sep 5, 2013
Service Brakes

WHILE TRAVELING ON THE PA TURNPIKE AT APPROX. 60 MPH, TRAFFIC SUDDENLY SLOWED IN FRONT OF ME. I WAS PULLING OUR 30 FIFTH WHEEL CAMPER AT THE TIME. I APPLIED THE BRAKE HARD HAD A SPLIT SECOND OF BRAKING ACTION AND THEN THE BRAKE PEDAL WENT TO THE FLOOR. I WAS ABLE TO USE THE MANUAL TRAILER BRAKE CONTROL TO SLOW THE TRUCK SOME, SW…

Read full complaint

WHILE TRAVELING ON THE PA TURNPIKE AT APPROX. 60 MPH, TRAFFIC SUDDENLY SLOWED IN FRONT OF ME. I WAS PULLING OUR 30 FIFTH WHEEL CAMPER AT THE TIME. I APPLIED THE BRAKE HARD HAD A SPLIT SECOND OF BRAKING ACTION AND THEN THE BRAKE PEDAL WENT TO THE FLOOR. I WAS ABLE TO USE THE MANUAL TRAILER BRAKE CONTROL TO SLOW THE TRUCK SOME, SWERVED INTO THE LEFT LANE MISSING THE CAR IN FRONT OF ME BY INCHES AND THE CAR TO THE LEFT OF ME SWERVED INTO THE FAR LEFT LANE TO AVOID HITTING ME. (THREE LANE HIGHWAY) I MANAGED TO DRIVE THE TRUCK TO A REST AREA ABOUT A MILE DOWN THE ROAD USING BOTH THE TRAILER BRAKES AND THE TRUCK EMERGENCY BRAKES. THE CAUSE OF THE BRAKE FAILURE WAS THAT THE BRAKE LINE LOCATED UNDER THE DRIVERS AREA HAD RUSTED THROUGH AND RUPTURED. *JB

NHTSA ODI #10541983

Mileage unknown · Aug 29, 2013
Service Brakes

EXPERIENCED A COMPLETE LOSS OF SERVICE BRAKES. FORTUNATELY THIS OCCURED AFTER COMPLETING A TRIP WHILE TOWING A TRAILER. HAD THIS HAPPENED DURING THE TRIP SERIOUS INJURIES AND MULTIPLE DEATHS COULD HAVE BEEN THE RESULT. INVESTIGATION OF THE PROBLEM INDICATED PREMTURE RUSTING THROUGH OF THE STEEL BRAKE LINE TO THE RIGHT FRONT D…

Read full complaint

EXPERIENCED A COMPLETE LOSS OF SERVICE BRAKES. FORTUNATELY THIS OCCURED AFTER COMPLETING A TRIP WHILE TOWING A TRAILER. HAD THIS HAPPENED DURING THE TRIP SERIOUS INJURIES AND MULTIPLE DEATHS COULD HAVE BEEN THE RESULT. INVESTIGATION OF THE PROBLEM INDICATED PREMTURE RUSTING THROUGH OF THE STEEL BRAKE LINE TO THE RIGHT FRONT DISC BRAKE. THE BRAKE LINE TO THE LEFT FRONT CALIPER IS ALSO BADLY RUSTED. THE BRAKE LINES FROM THE MASTER CYLINDER ARE MILDLY RUSTED AS WELL.

NHTSA ODI #10537840

99,600 miles · Aug 11, 2013
Service Brakes

GOT IN VEHICLE, STARTED IT,PUT IN GEAR,APPLIED BRAKE AND PEDAL DEPRESSED FARTHER THAN USUAL, HIT AGAIN THEY WENT ALMOST TO FLOOR.GOT OUT AND SAW BRAKE FLUID ON FRAME WHERE LINE HAD RUSTED IN THROUGH.UPON INSPECTION ALL LINES ARE TERRIBLY RUSTED AND WILL NEED REPLACED. *TR

NHTSA ODI #10534707

44,766 miles · Jun 25, 2013
Service Brakes

MY BRAKE LINES RUSTED AT THE REAR OF THE LT FRONT WHEEL SPLASH AREA. THIS VEHICLE HAS LOW MILES FOR THE YEAR AND WAS NOT DRIVEN IN SALT OR DEICE. THE BRAKE LINE SHOULD NOT NEED TO BE REPLACED AT THIS TIME WITH SO MUCH SERVICE LIFE LEFT. I WAS LUCKY, THE BRAKE LINE BURST IN MY DRIVEWAY. *TR

NHTSA ODI #10521677

104,801 miles · Apr 19, 2013
Service Brakes

RUSTY BRAKE LINES ON 2004 GMC 2500HD SIERRA. ALMOST CAUSED ME TO HAVE AN ACCIDENT BECAUSE THE BRAKE PETAL WENT TO THE FLOOR IMMEDIATELY WHEN THE BRAKE LINE BURST. I HAVE PICTURES OF THE OLD RUSTED BRAKE LINES IF YOU WOULD LIKE TO SEE THE PICTURES. SINCE IT SEEMS TO BE A WIDE SPREAD PROBLEM ON GM PICKUP TRUCKS FROM RESEARCHING…

Read full complaint

RUSTY BRAKE LINES ON 2004 GMC 2500HD SIERRA. ALMOST CAUSED ME TO HAVE AN ACCIDENT BECAUSE THE BRAKE PETAL WENT TO THE FLOOR IMMEDIATELY WHEN THE BRAKE LINE BURST. I HAVE PICTURES OF THE OLD RUSTED BRAKE LINES IF YOU WOULD LIKE TO SEE THE PICTURES. SINCE IT SEEMS TO BE A WIDE SPREAD PROBLEM ON GM PICKUP TRUCKS FROM RESEARCHING IT ON THE INTERNET, I'M CURIOUS TO KNOW WHEN THEY ARE GOING TO RECALL THEM? JUST SAW ON THE NEWS WHERE THERE IS A GOVERNMENT RECALL ON 2005-2009 SUBARU'S FOR THE SAME PROBLEM. IT COST $1290.00 TO REPAIR ALL THE BRAKE LINES. *TR

NHTSA ODI #10508778

31,915 miles · Dec 13, 2012
Service Brakes

I WAS APPROACHING A ONE LANE COVERED BRIDGE ON THE WAY HOME FROM WORK AND ANOTHER APPROACHING VEHICLE FAILED TO YIELD. I MADE AN EMERGENCY STOP BY PRESSING FIRMLY ON THE BRAKES. BRAKE PEDAL WENT RIGHT TO THE FLOOR. I HAD TO QUICKLY USE MY FOOT OPERATED EMERGENCY/PARKING BRAKE TO STOP FROM HAVING A HEAD ON COLLISION. I HAD TO…

Read full complaint

I WAS APPROACHING A ONE LANE COVERED BRIDGE ON THE WAY HOME FROM WORK AND ANOTHER APPROACHING VEHICLE FAILED TO YIELD. I MADE AN EMERGENCY STOP BY PRESSING FIRMLY ON THE BRAKES. BRAKE PEDAL WENT RIGHT TO THE FLOOR. I HAD TO QUICKLY USE MY FOOT OPERATED EMERGENCY/PARKING BRAKE TO STOP FROM HAVING A HEAD ON COLLISION. I HAD TO PAY CLOSE TO $1200 TO HAVE THE ENTIRE BRAKE LINE SYSTEM REPLACED DUE TO SEVERE RUST OF THE BRAKE LINES. I AM VERY FORTUNATE THAT THIS TURNED OUT THE WAY IT DID. MY LIFE AND THE LIVES OF OTHERS ARE BEING ENDANGERED BY GM NOT USING A MATERIAL THAT IS RESISTANT TO CORROSION. *TR

NHTSA ODI #10488732

93,000 miles · Dec 5, 2012
Service Brakes

BRAKE LINES RUSTED THROUGH. ALL BRAKE FLUID LEAKED OUT. NO BRAKE SYSTEM INCLUDING EMERGENCY BRAKE FAILED. HAD TO STOP VEHICLE AGAINST CURB SYSTEM. *TR

NHTSA ODI #10487416

126,000 miles · Nov 11, 2012
Service Brakes

COMPLETE BRAKE FAILURE, WHEN BRAKE LINE BLEW OUT WHILE TRYING TO STOP. PRIOR TO HITTING CAR IN FRONT, SWERVED INTO LEFT TURN LANE AND APPLIED EMERGENCY BRAKE. *TR

NHTSA ODI #10483980

140,894 miles · Nov 5, 2012
Service Brakes

TL* THE CONTACT OWNS A 2004 GMC SIERRA 2500 HD. THE CONTACT STATED THAT WHILE DRIVING 40 MPH THE VEHICLE BEGAN TO SHAKE VIOLENTLY. THE CONTACT MENTIONED THAT THE VEHICLE WAS MERGED TO THE SIDE OF THE ROAD AND AFTER A FEW MINUTE RESTARTED THE VEHICLE BUT THE FRONT WHEEL WAS LOCKED AND SMOKE WAS EMITTING FROM THE HUBCAPS. AFTER A …

Read full complaint

TL* THE CONTACT OWNS A 2004 GMC SIERRA 2500 HD. THE CONTACT STATED THAT WHILE DRIVING 40 MPH THE VEHICLE BEGAN TO SHAKE VIOLENTLY. THE CONTACT MENTIONED THAT THE VEHICLE WAS MERGED TO THE SIDE OF THE ROAD AND AFTER A FEW MINUTE RESTARTED THE VEHICLE BUT THE FRONT WHEEL WAS LOCKED AND SMOKE WAS EMITTING FROM THE HUBCAPS. AFTER A CONSIDERABLE AMOUNT OF TIME THE WHEELS UNLOCKED AND THE VEHICLE WAS DRIVEN TO A DEALER FOR DIAGNOSIS. HE WAS INFORMED THAT THE SEAL IN THE BOOST HAD LEAKED AND CONTAMINATED BRAKE FLUID AND LOCKED UP THE SYSTEM. THE VEHICLE WAS REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 140,894. UPDATED 12/19/12 *CN THE CONSUMER STATED WHILE TRAVELING 40MPH THE VEHICLE STARED LOSING POWER. UPON FURTHER INSPECTION IT WAS FOUND THE BRAKES WERE SMOKING. AFTER THE SMOKE SETTLED, THE CONSUMER ATTEMPTED TO PRESS THE BRAKE PEDAL. IT WOULD NOT MOVE. AFTER ABOUT 3 HOURS THE BRAKES RELEASED. THE VEHICLE WAS THEN DRIVEN T A REPAIR SHOP. UPDATED 1/9/2013 *JS

NHTSA ODI #10483364

102,000 miles · Oct 8, 2012
Service Brakes

BRAKE LINES ALL ROTTED AWAY NEAR ABS MODULE MOUNTED IN FRAME. I HAD TO TAKE TO A SHOP TO GET ALL LINE REPLACE FROM ABS MODULE FORWARD. THIS TRUCK HAS NEVER BEEN NEAR SALT EVER. 100,000 MILES AND ALREADY RELINING THE TRUCK! FUEL LINES LOOK LIKE THEY ONLY HAVE A FEW MONTHS LEFT. THIS IS A DANGER AND A HUGE WASTE OF MONEY FOR A BUY…

Read full complaint

BRAKE LINES ALL ROTTED AWAY NEAR ABS MODULE MOUNTED IN FRAME. I HAD TO TAKE TO A SHOP TO GET ALL LINE REPLACE FROM ABS MODULE FORWARD. THIS TRUCK HAS NEVER BEEN NEAR SALT EVER. 100,000 MILES AND ALREADY RELINING THE TRUCK! FUEL LINES LOOK LIKE THEY ONLY HAVE A FEW MONTHS LEFT. THIS IS A DANGER AND A HUGE WASTE OF MONEY FOR A BUYER I HAVE HAD OTHER GM CARS THAT ARE 30 YEARS OLD WITH 350,000 MILES WITH FACTORY BRAKE AND FUEL LINES. *TR

NHTSA ODI #10479228

Official recalls

1

04V562000 · Equipment Adaptive/mobility

Nov 26, 2004

ON CERTAIN VANS EQUIPPED WITH SURE-LOK WHEELCHAIR SECUREMENT SYSTEMS, THE SPROCKET TEETH OF THE RETRACTOR ASSEMBLY IS OUT OF ALIGNMENT.

Consequence & remedy

Consequence: IN THE EVENT OF A VEHICLE CRASH, THE WHEELCHAIR MAY NOT BE ADEQUATELY SECURED POSSIBLY RESULTING IN INJURIES TO A WHEELCHAIR OCCUPANT.

Remedy: 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.

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.