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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
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…

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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

63,000 miles · Apr 5, 2013
Electrical System

TL* THE CONTACT OWNS A 2004 GMC SIERRA 2500. THE CONTACT STATED THAT THE INSTRUMENT PANEL CHANGED THE DISPLAY AND LANGUAGE INDEPENDENTLY. THE VEHICLE WAS NOT TAKEN TO THE DEALER. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 63,000. *TR

NHTSA ODI #10507284

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…

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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

50,000 miles · Dec 5, 2012
Engine

TL* THE CONTACT OWNS A 2004 GMC SIERRA 2500 HD. THE CONTACT STATED THAT WHILE DRIVING VARIOUS SPEEDS HE WOULD HEAR A LOUD NOISE COMING FROM THE ENGINE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSIS WHERE THE CONTACT WAS ADVISED THAT THE MANIFOLD BOLTS WERE FRACTURED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT…

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TL* THE CONTACT OWNS A 2004 GMC SIERRA 2500 HD. THE CONTACT STATED THAT WHILE DRIVING VARIOUS SPEEDS HE WOULD HEAR A LOUD NOISE COMING FROM THE ENGINE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSIS WHERE THE CONTACT WAS ADVISED THAT THE MANIFOLD BOLTS WERE FRACTURED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. IN ADDITION, THE CONTACT ALSO NOTICED THAT THE INSTRUMENT CLUSTER FAILED AND HE WAS UNABLE TO DETERMINE WHAT SPEED HE WAS TRAVELING, HOW MUCH FUEL WAS IN THE VEHICLE, ETC. THE VEHICLE WAS TAKEN FOR INSPECTION WHERE THE CONTACT WAS ADVISED THAT THE CLUSTER WIRING FAILED AND NEEDED TO BE REPLACED. THE MANUFACTURER WAS CONTACTED HOWEVER, THEY OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 50,000. THE CURRENT MILEAGE WAS APPROXIMATELY 53,000.

NHTSA ODI #10487473

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 …

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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…

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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

56,000 miles · Oct 3, 2012
Tires

TL* THE CONTACT OWNS A 2004 GMC CK2500 HD EQUIPPED WITH COOPER DEAN MUD TERRAIN RADIAL SXT TIRES, SIZE LT265/75R16. THE CONTACT STATED THAT WHILE DRIVING 65 MPH, THERE WAS A HEAVY VIBRATION FELT WITHIN THE VEHICLE AS THE FRONT DRIVER'S SIDE TIRE EXPLODED. THE VEHICLE BECAME UNCONTROLLABLE AND VEERED FROM THE RIGHT LANE TO THE CE…

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TL* THE CONTACT OWNS A 2004 GMC CK2500 HD EQUIPPED WITH COOPER DEAN MUD TERRAIN RADIAL SXT TIRES, SIZE LT265/75R16. THE CONTACT STATED THAT WHILE DRIVING 65 MPH, THERE WAS A HEAVY VIBRATION FELT WITHIN THE VEHICLE AS THE FRONT DRIVER'S SIDE TIRE EXPLODED. THE VEHICLE BECAME UNCONTROLLABLE AND VEERED FROM THE RIGHT LANE TO THE CENTER MEDIAN BEFORE STOPPING. THE VEHICLE WAS TOWED TO THE DEALER WHO REPLACED THE TIRE. THE MANUFACTURER WAS NOT NOTIFIED. THE FAILURE MILEAGE WAS 56,000 AND THE FAILURE MILEAGE OF THE TIRE WAS 17,000. UPDATED 10/22/12 *BF UPDATED 10/22/12. *JB

NHTSA ODI #10478515

87,000 miles · Sep 18, 2012
Service Brakes

LEAVING WORK I PULLED OUT FROM THE PARKING LOT AND DROVE ABOUT 500 YARDS. WENT TO APPLY BRAKES AND PEDAL WENT TO THE FLOOR. I WAS ABLE TO MAKE IT BACK TO MY WORK PARKING LOT AND STOPPED THE TRUCK. NOTICED THAT BRAKE FLUID WAS POURING FROM UNDER THE TRUCK IN TWO PLACES. ONE LEAK WAS UNDER THE DRIVERS AREA AND THE OTHER WAS IN…

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LEAVING WORK I PULLED OUT FROM THE PARKING LOT AND DROVE ABOUT 500 YARDS. WENT TO APPLY BRAKES AND PEDAL WENT TO THE FLOOR. I WAS ABLE TO MAKE IT BACK TO MY WORK PARKING LOT AND STOPPED THE TRUCK. NOTICED THAT BRAKE FLUID WAS POURING FROM UNDER THE TRUCK IN TWO PLACES. ONE LEAK WAS UNDER THE DRIVERS AREA AND THE OTHER WAS IN FRONT OF THE LEFT REAR WHEEL. THE PLACE I WORK HAS A CAR LIFT. PUT THE TRUCK ON THE LIFT AND THE BRAKE LINES WERE RUSTED THROUGH. THE TRUCK HAS ENORMOUS AMOUNTS OF RUST ON THE FRAME, SUSPENSION, AND AXLES. THIS TRUCK IS NOT MY DAILY DRIVER. I DO NOT LIVE NEAR THE OCEAN NOR DO I PUSH SNOW WITH IT. I HAVE NEVER SEEN BRAKE LINES RUST OUT LIKE THIS. GM STATED THAT I HAD TO TAKE IT TO A DEALER FOR INSPECTION. AFTER READING UP ON THE TOPIC I KNOW GM WON'T DO ANYTHING ABOUT THE LINES. I ALREADY ORDERED STAINLESS STEEL BRAKE LINES FOR THE TRUCK AND WILL INSTALL THEM. HOPEFULLY GM WILL REIMBURSE OWNER FOR THIS EXPENSE. *TR

NHTSA ODI #10475854

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.