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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

What owners actually said

143 reports
169,000 miles · Mar 4, 2014
Service Brakes

BRAKE PEDAL WENT TO THE FLOOR. ALMOST IMPOSSIBLE TO DRIVE LIKE THAT. TAKES OVER 100X LONGER TO STOP A 3/4 TON TRUCK. I FOUND THAT THE BRAKE LINES RUSTED OUT. I ALSO FOUND SEVERAL HUNDRED REPORTS OF THE SAME THINGS ON GM TRUCK ONLINE. I ALSO HEARD YOU WERE INVESTIGATING THIS ISSUE ALREADY. I WANTED TO MAKE SURE I AM COUNTED AS ON…

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BRAKE PEDAL WENT TO THE FLOOR. ALMOST IMPOSSIBLE TO DRIVE LIKE THAT. TAKES OVER 100X LONGER TO STOP A 3/4 TON TRUCK. I FOUND THAT THE BRAKE LINES RUSTED OUT. I ALSO FOUND SEVERAL HUNDRED REPORTS OF THE SAME THINGS ON GM TRUCK ONLINE. I ALSO HEARD YOU WERE INVESTIGATING THIS ISSUE ALREADY. I WANTED TO MAKE SURE I AM COUNTED AS ONE OF THE EFFECTED PEOPLE. I ALSO READ WHERE GM DOES NOT CONSIDER THIS A SAFETY ISSUE. I DISAGREE. THE LINE FROM THE MASTER CYLINDER TO THE ABS UNIT BLEW SO I HAD ZERO BRAKE PRESSURE AND PEDAL. I THINK THIS SHOULD BE RECALLED AS IT IS A HUGE SAFETY ISSUE. I HAVE ALREADY SPENT OVER $1000 AND A WEEK TRYING TO FIX THIS AND REPLACE ALL THE RUSTED LINE. I STILL DO NOT HAVE THE TRUCK BACK ON THE ROAD. THANKS *TR

NHTSA ODI #10567069

98,000 miles · Feb 4, 2014
Service Brakes

TL* THE CONTACT OWNS A 2004 GMC SIERRA 2500. THE CONTACT STATED THAT THE BRAKE FAILED TO ENGAGE WHILE ATTEMPTING TO APPLY THE BRAKE PEDAL WHILE DRIVING 35 MPH. THE VEHICLE WAS TOWED TO A LOCAL MECHANIC FOR INSPECTION THAT CONFIRMED THAT THE BRAKE LINES WERE CORRODED. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS NOT AVAILABLE. THE…

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TL* THE CONTACT OWNS A 2004 GMC SIERRA 2500. THE CONTACT STATED THAT THE BRAKE FAILED TO ENGAGE WHILE ATTEMPTING TO APPLY THE BRAKE PEDAL WHILE DRIVING 35 MPH. THE VEHICLE WAS TOWED TO A LOCAL MECHANIC FOR INSPECTION THAT CONFIRMED THAT THE BRAKE LINES WERE CORRODED. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS NOT AVAILABLE. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE AND CURRENT MILEAGE WAS 98,000.

NHTSA ODI #10562816

77,610 miles · Sep 17, 2013
Service Brakes

WHEN ATTEMPTING TO STOP, THE TRUCK BEGAN TO STOP AND THEN ALL OF A SUDDEN THE BRAKE PEDAL WENT TO THE FLOOR. AT THIS POINT THERE WERE NO BRAKES AT ALL. THANKFULLY NO ONE WAS IN FRONT OF ME SO I WAS ABLE TO COAST UNTIL THE VEHICLE SLOWED, AND THEN USE THE E-BRAKE TO SLOW DOWN ENOUGH TO TURN. UPON FURTHER INSPECTION, A BRAKE LI…

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WHEN ATTEMPTING TO STOP, THE TRUCK BEGAN TO STOP AND THEN ALL OF A SUDDEN THE BRAKE PEDAL WENT TO THE FLOOR. AT THIS POINT THERE WERE NO BRAKES AT ALL. THANKFULLY NO ONE WAS IN FRONT OF ME SO I WAS ABLE TO COAST UNTIL THE VEHICLE SLOWED, AND THEN USE THE E-BRAKE TO SLOW DOWN ENOUGH TO TURN. UPON FURTHER INSPECTION, A BRAKE LINE HAD BROKEN. *TR

NHTSA ODI #10543984

80,000 miles · Sep 13, 2013
Service Brakes

TL* THE CONTACT OWNS A 2004 GMC SIERRA 2500 HD. THE CONTACT STATED THAT WHILE DRIVING 40 MPH, HE APPLIED THE BRAKES BUT THE VEHICLE DID NOT RESPOND. HE CONTINUED APPLYING PRESSURE UNTIL THE PEDAL TOUCHED THE FLOORBOARD AND FINALLY, THE VEHICLE CAME TO A STOP. THE VEHICLE WAS TAKEN TO A DEALER FOR DIAGNOSIS AND THE CONTACT WAS IN…

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TL* THE CONTACT OWNS A 2004 GMC SIERRA 2500 HD. THE CONTACT STATED THAT WHILE DRIVING 40 MPH, HE APPLIED THE BRAKES BUT THE VEHICLE DID NOT RESPOND. HE CONTINUED APPLYING PRESSURE UNTIL THE PEDAL TOUCHED THE FLOORBOARD AND FINALLY, THE VEHICLE CAME TO A STOP. THE VEHICLE WAS TAKEN TO A DEALER FOR DIAGNOSIS AND THE CONTACT WAS INFORMED THAT THE STEEL BRAKE LINES EXHIBITED MASSIVE CORROSION AND WERE LEAKING. THE VEHICLE WAS TAKEN TO A DIFFERENT DEALER WHERE THE REPAIR WAS COMPLETED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE AND CURRENT MILEAGE WAS 80,000.

NHTSA ODI #10543468

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…

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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…

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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

132,000 miles · Jun 8, 2013
Engine

VEHICLE HAS EXPERIENCED MULTIPLE INSTANCES OF EXHAUST MANIFOLD BOLT FAILURES AT THE CYLINDER HEAD ON BOTH BANKS OF THE ENGINE. *TR

NHTSA ODI #10515806

118,000 miles · May 14, 2013
Fuel System, Diesel

DIESEL FUEL LEAKS FROM INJECTORS INTO ENGINE OIL PAN AND CONTAMINATES ENGINE OIL THEM LEAKS OIL FROM BREATHER & REAR MAIN OIL SEAL AND GM KNOWS THERE IS A PROBLEM BUT WONT DO ANY THING FOR THIS PROBLEM SAID ITS OUT WARRANTY ON TIME NOT MILES. *TR

NHTSA ODI #10511935

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.