The bolts attaching the exhaust manifold to the engine are broken off causing exhaust leaks both side motor. The cab of this vehicle sits over the motor so you can smell raw exhaust inside the vehicle.. There are several complaints posted online and youtube about this problem. I have a friend that has a similar truck to mine and he has same problem.
The worst 2004 Chevrolet W3500 problems
Ranked by number of owner complaints. Mileage and cost come from what owners wrote.
- Engine2
- Body1
- Brakes1
- Electrical1
- Fuel system1
Problems by type
Tap a problem to see which part fails, at what mileage and in which other years.
- Engine2
- Body1
- Brakes1
- Electrical1
- Fuel system1
- Suspension1
Recalls 1
Fuel system, diesel: storage: tank assembly
- What is wrong
- On certain trucks equipped with rpo ik9, due to insufficient durability and testing, the fuel switching manifold solenoids lack water or salt intrusion resistance, which can lead to failure of one or more solenoids. Fuel switching manifold solenoid failure will cause incorrect fuel delivery resulting in fuel overflow from the fuel filler neck.
- Risk
- Overflow fuel may result in high amount of diesel fuel leakage. Fuel leakage, in the presence of an ignition source, could result in a fire.
- Remedy
- Dealers will replace the solenoid valve assembly with an improved assembly including additional detection circuit and enhanced water resistance free of charge. The recall began on october 27, 2005. Owners may contact isuzu at 1‑800‑255‑6727.
Recall number 05V168000 · Recall details
Technical service bulletins for the 2004 Chevrolet W3500 80
Bulletins tell dealers how to fix known problems. A warranty extension means the manufacturer pays for that repair for longer.
- This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.
- Unknown or other
- Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles
- GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities
- This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves...
- This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as...
- This Warranty Administration bulletin provides retail and wholesale service personnel with the...
- This bulletin provides information for electrical ground repairs using new General Motors replacement...
- This technical bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake...
- This service bulletin provides service information to technicians on guidelines to replace Oil Cooler, Oil...
What 2004 Chevrolet W3500 owners say
Most recent owner complaints, unedited.
Tl*the contact owns a 2004 chevrolet c3500 truck. The contact stated that the exhaust system is leaking. Fumes emitted throughout the cabin when the engine was in operation. The contact was in the process of performing a diagnostic test to determine the cause of failure. The failure mileage was approximately 152,000. Updated 05/24/11*lj the consumer stated the vehicle has a cracked exhaust manifold. Updated 05/26/11
Vehicle was towing a trailer. When the left rear shock mount broke off the axle. The brake line is bolted to the shock mount. When the mount broke, it took out the brake line, watch resulted in the lose of brakes. After having a welder look at the bracket we came to the conclusion that the welds from the factory were to cold to penetrate the bracket or the axle. We put new brake line on and remounted the shock bracket to axle. We rerouted the brake line so it was not on the shock mount.
While driving 65 MPH vehicle stalled. Vehicle was towed to the dealer for inspection, and mechanic determined that fuel pump, computer sensor, and fuel line needed to be replaced ,and replaced them. However, the problem recurred.
Compare the 2004 Chevrolet W3500
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Questions about the 2004 Chevrolet W3500
Is the 2004 Chevrolet W3500 reliable?
Owners have filed 4 complaints about the 2004 Chevrolet W3500, 2.0 times a typical W3500 model year.
What is the most common problem with the 2004 Chevrolet W3500?
Engine and cooling, with 2 complaints. Next is body (1).
How many recalls does the 2004 Chevrolet W3500 have?
1 recall, covering fuel system, diesel.
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