2003 Chevrolet C4500 Problems
Owner-reported complaints filed with NHTSA, grouped by component
Data refreshed
What this page shows
Everything below is an owner-reported complaint submitted to NHTSA about the 2003 Chevrolet C4500, grouped by the component NHTSA recorded on the report. These are not confirmed defects, and they are not recalls. NHTSA does not verify most reports before publishing them, and a category with more reports in it is not evidence that a part is defective.
Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.
Reports by component
Ranked by how many owner reports name each component category
- Engine342.9%
- Electrical228.6%
- Fuel system114.3%
- Suspension114.3%
Percentages are of component mentions. A single complaint can name more than one component, so these do not sum to the total complaint count.
Each component in detail
What the reports in each category say, in the owners' own words
Engine
Reports naming the engine itself — including stalling, misfires, oil consumption, cooling and internal engine components.
From owner reports, verbatim
DT*: THE CONTACT STATED WHEN DRIVING AT ANY SPEED, THE VEHICLE STALLED INTERMITTENTLY. WHEN THE IGNITION WAS TURNED OFF, THE VEHICLE WOULD RESTART WITHOUT A PROBLEM. THE DEALERSHIP REPLACED THE FUEL PUMP AND EXCHANGE PUMP, ALTHOUGH THIS HELPED THE STALLING, IT DID NOT CORRECT THE PROBLEM. THE STALLING PROGRESSIVELY GOT WORSE. THE DEALERSHIP IS UNABLE TO DETERMINE A PROBLEM.
WHILE DRIVING 60 MPH VEHICLE STALLED. CONSUMER WAS UNABLE TO RESTART VEHICLE, AND HAD IT TOWED TO THE DEALER FOR INSPECTION. MECHANIC DETERMINED THAT THE TEMPERATURE SENSOR NEEDED TO BE REPLACED, AND REPLACED IT. HOWEVER, THE PROBLEM RECURRED, AND VEHICLE WAS TAKEN BACK TO THE DEALER . MECHANIC REPLACED THE COMPUTER SENSOR, AND THE PROBLEM RECURRED AGAIN. *AK
Too few reports in this category for a page of its own — they appear in the full complaint list.
Electrical
Reports naming the electrical system — wiring, battery, charging, control modules, infotainment and electrical accessories.
From owner reports, verbatim
THE 2003 CHEVROLET KODIAK C-4500 CREW CAB TRUCK COMES STANDARD WITH A FACTORY INSTALLED EXHAUST BRAKE. WHEN THE BRAKE IS ENGAGED, NO BRAKE LIGHTS COME ON AT THE REAR OF THE VEHICLE. THIS SIZE TRUCK IS COMMONLY USED TO HAUL RV TRAILERS, FIFTH WHEEL TRAILERS AND HORSE TRAILERS. SINCE THE BRAKE LIGHTS ARE NOT ACTIVATED ON THE TRUCK, NEITHER ARE THEY ACTIVATED ON THE REAR OF THE TRAILER. WHEN ACTIVATING THE EXHAUST BRAKE WHILE GOING DOWN A STEEP HILL, THE VEHICLE AND TRAILER CAN BE SLOWING DOWN, BUT NOT GIVE ANY INDICATION TO A FOLLOWING VEHICLE. THIS IS A VERY DANGEROUS SITUATION. I ASKED THE GM ENGINEERS TO SEND ME A WIRING DIAGRAM TO FIX THIS BUT THEY REFUSED, CLAIMING THAT IT WAS A SAFETY ISSUE IF THE SYSTEM WAS REWIRED. THERE ARE CURRENTLY 2003 AND 2004 CLASS A MOTOR HOMES WIRED IN THE MANNER I'M SUGGESTING. ON THESE VEHICLES, WHEN THE EXHAUST BRAKE IS ACTIVATED, THE REAR BRAKE LIGHTS ALSO ACTIVATE WARNING ANYONE FOLLOWING THAT THE LEADING VEHICLE IS SLOWING DOWN. *NM
WHILE DRIVING 60 MPH VEHICLE STALLED. CONSUMER WAS UNABLE TO RESTART VEHICLE, AND HAD IT TOWED TO THE DEALER FOR INSPECTION. MECHANIC DETERMINED THAT THE TEMPERATURE SENSOR NEEDED TO BE REPLACED, AND REPLACED IT. HOWEVER, THE PROBLEM RECURRED, AND VEHICLE WAS TAKEN BACK TO THE DEALER . MECHANIC REPLACED THE COMPUTER SENSOR, AND THE PROBLEM RECURRED AGAIN. *AK
Too few reports in this category for a page of its own — they appear in the full complaint list.
Fuel system
Reports naming fuel storage or delivery — tanks, pumps, lines, injectors and fuel leaks.
From owner reports, verbatim
AFTER MONTHS OF HARD STARTING THE ENGINE, THINKING IT WAS THE COLD WEATHER, OLDER GLOW PLUGS, IT TURNED OUT TO BE NOT ENOUGH PRESSURE IN THE FUEL SYSTEM. THE FUEL INJECTORS ARE LEAKING DIESEL FUEL INTO THE CRANKCASE. CHEVY HAS KNOW OF THIS PROBLEM FOR SOME TIME. THEY WANT 4500.00 TO REPLACE THE INJECTORS. THE OIL IS CONTAMINATED AND CAN CATCH ON FIRE. I DO NOT KNOW IF THERE IS FURTHER DAMAGE TO THE CYLINDERS OR PISTONS OR OTHER COMPONENTS DUE TO DRIVING WITH CONTAMINATED OIL. CHEVY SAYS TO BAD. ROLL THE DICE ON THE REPAIR OR BUY A NEW TRUCK. EASY FOR THEM TO SAY, IT IS NOT THEIR HARD WORK OR MONEY THAT HAS TO PAY FOR THEIR DEFECT. CHEVY HAS CHANGED THE DESIGN OF THE NEW FUEL INJECTOR,KNOWING THE OLD ONE WAS FAULTY. READING ONLINE FOR DURAMAX ENGINES [CHEVY KODIAK AND THEN SOME] IT AM FINDING OUT THIS IS A COMMON PROBLEM. ALSO READING WHERE CHEVY IS NOT STANDING UP FOR WHAT THEY KNOW IS A PROBLEM. AFTER TALKING TO THE SERVICE DEPT AT THE LOCAL CHEVY DEALER AND GM HEADQUARTERS, THEY BOTH SAY THIS IS A COMMON PROBLEM. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
Too few reports in this category for a page of its own — they appear in the full complaint list.
Suspension
Reports naming suspension components — springs, struts, shocks, control arms and related hardware.
From owner reports, verbatim
CONSUMER COMPLAINED ABOUT AN ENGINE PROBLEM. IT DID NOT MAINTAIN THE THROTTLE. ENGINE WENT INTO NEUTRAL WITHOUT A CAUSE. ALSO, A SUSPENSION PROBLEM DUE TO BOLTS PLACED IN UPSIDE DOWN POSITION WHICH CAUSED VEHICLE TO FLIP. WIRES AND PLASTIC BOLT HOLDERS MELTED.*AK
Too few reports in this category for a page of its own — they appear in the full complaint list.
Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers.
Elsewhere on this vehicle
Data sources
- NHTSA Office of Defects Investigation — owner-reported complaints and the components recorded on them
Data on this page last refreshed .