2004 Chevrolet Silverado 3500 problems

Filed Sep 16, 2017 · Brakes · 104,000 miles · TX

All factory hard brake lines have failed due to corrosion. I've replaced the intermediate line between the master cylinder and distribution block with stainless steel 1.5 yrs ago. I just replaced the rear brake lines along the axel. Now the front brake lines have failed. In all cases the lines failed while driving and emptied the master cylinder. I do not live in the salt belt.

Filed Nov 22, 2016 · Brakes · 248,000 miles · KY

Brake line failure due to rusted & corroded brake lines resulting in costly repairs. Luckily my 2004 chevy silverado 3500 was stationary when brake line ruptured and I was not towing a trailer or loaded with cargo at the time of failure. The ABS pump also failed prior to line failure. My father in law had similar issues with the same model year 1500. Why does gm not use stainless brake lines for such an important safety component.

Filed Mar 14, 2016 · Brakes, Fuel system · 136,000 miles · NC

2 problems: 1- while driving with no warning the brakes failed. After coasting to a stop I noticed a brake line had ruptured at the frame rail under driver area. I was able to crimp brake line with a pair of vice grip pliers and move truck to a safe location for repair. I believe the brake lines used on these trucks to be of such inferior quality that sudden failure is a common occurrence. 2- my truck has dual tanks for diesel fuel and they have worked sporadically for years. I did not see this as a safety issue as much as an inconvenience. However while my truck was idling on a hot summer day I noticed diesel fuel dripping out of the front tank filler cap. Apparently the pump that pumps the fuel from the rear tank to the front tank was receiving a signal to pump even though the front tank was completely filled. It was continuing to pump and leaking the fuel out the filler neck. This seems like a serious safety hazard to me. I do not know if the root of the problem is the float that sticks in the rear tank, the sending units that fail, a wiring ground issue or some other electronic glitch. I do know issues with dual tank duramax diesel trucks are about as common as the truck itself is. After researching online I realized many other owners of my vehicle model have had both of the exact same problems so I thought I should report them.

Filed Feb 23, 2016 · Body · 40,000 miles · MN

Tl* the contact owns a 2004 chevrolet silverado 3500. The contact stated that the rocker panels located under the doors on both the driver and passenger side of the vehicle were rusted and corroded. The vehicle was taken to the dealer who did not repair the vehicle. The contact indicated that the steel inside the rocker panel was not painted and contributed to the rusting. The cause of the failure was not diagnosed or repaired. The manufacturer was not notified of the failure. The VIN was not availiable. The failure mileage was 40,000.

Filed May 9, 2015 · Brakes · 103,000 miles · IA · crash

Front brake lines failed causing fluid loss and complete loss of brakes. Happened at slow speed, but still was unable to stop before hitting a fixed object

Filed Apr 28, 2015 · Brakes · 100,000 miles · OH

In march while driving my 2004 chevy 3500 diesel truck the brake warning lights inside the cab lit up and the brake pedal was feeling spongy. I took it into classic auto group mentor for service. A wheel bearing was replaced along with a few other items and I was told that it was good to go. I picked it up. The brake pedal was still spongy and the warning lights were still on. On april 22, I returned to the classic auto group chevy service to again have the brakes serviced. They billed me $1400.00 to change a valve, a module and some screws. The brakes now go all the way down to the floor when depressed with the motor running. There is no effective braking ability. With no effective braking the warning lights are not lit up. Classic auto group chevy in mentor says that this is normal. This is not how the brakes worked before the warning lights came on. They worked like brakes on any vehicle. Classic auto group mentor says that I should just get used to it. I have a complaint number from chevy # [xxx] information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6).

Filed Apr 15, 2015 · Engine · 45,557 miles · CT

Ticking under hood. Exhaust leak due to broken exhaust manifold bolt passenger side near firewall. Tried to loosen other bolts, 3 more broke. Truck has very low miles, 8.1l motor. Internet shows thousands of same issues. Bolts used are very thin for what they do.

Filed Mar 23, 2015 · Fuel system · GA

2004 chevrolet silverado 3500. Consumer writes in regards to engine injectors issue. *smd the consumer stated the injectors were replaced in 2010, and now then need to be replaced again.

Filed Sep 18, 2013 · Brakes · 68,914 miles · IN · crash

I was coming home from work this evening and was pulling up to the garage and the brakes failed causing me to hit the garage. I was traveling less than 5 MPH. The brake pedal went all the way to the floor and the vehicle would not stop. After getting out of the vehicle found brake fluid all over the driveway. Brake lines was found to be rusted in two in several places after having a friend who is a mechanic come and look at vehicle. He found a couple lines that had exploded thru right under the drivers side seat on top the frame and another one above the fuel tank. After googling what had happened there thousands of complaints with the federal safety agency on this problem with gm vehicles. Why are we paying you people to try and keep the public safe. This is a very ongoing problem with gm vehicles and needs addressed promptly.

Filed Aug 29, 2013 · Brakes · 74,000 miles · OH

Had just hooked up our 38' - 12,000lb fifth wheel and headed out for the weekend. Came to the first stop sign and the brake pedal went to the floor. Luckily got stopped with trailer brakes. After stopping, pumping brakes caused brake fluid to pour out from just in front of the driver's side rear wheel. Upon research when we arrived home, I find that this is an ongoing issue with chevrolet trucks.