2004 Chevrolet Silverado 2500 Fuel system Problems

CHECK ENGINE LIGHT CAME ON AND "LOW ENGINE POWER" FLASHED WHERE THE ODOMETER IS. THIS CAUSED THE RPM'S NOT TO GO OVER 2800. CODE READER CLAIMS O2 SENSORS OR THROTTLE CONTROL MODULE OR CATALYTIC CONVERTOR ISSUES. WE DISCOVERED IT WAS NONE OF THE ABOVE. TO FIX PROBLEM CHANGE 3 RELAYS LOCATED UNDER HOOD IN FUSE BOX. RELAY #8864. THEN CLEAR CODES, SHOULD FIX ISSUE UNLESS CODE PERSISTS. RELAYS WILL CAUSE A FIRE IF NOT CHANGED OUT ASAP.

NHTSA ID

11163966

Incident

Aug 22, 2018

Mileage

215,000 mi

I HAVE HAD A COMPLETE BRAKE JOB BECAUSE ALL OF THE LINES RUSTED OUT AND FAILED AS I WAS DRIVING. FORTUNATELY, I WAS ABLE TO USE THE EMERGENCY BRAKE TO STOP SAFELY. I SPENT ROUGH.Y $3,000 TO GET THIS REPAIRED. NOW THE FUEL LINES, FUEL COOLER AND EVERYTHING ATTACHED HAS RUSTED OUT TO THE POINT THAT IT IS GOING TO BE AN ADDITIONA $2,500 TO REPAIR THIS. ALSO, THE COMPLETE UNDER CARRIAGE AND REAR END HAS RUSTED TO THE POINT THAT I AM EXPECTING IT TO FAIL AT ANY TIME. THIS IS NOT ONLY A DANGEROUS SITUATION, BUT IS EXTREMELY COSTLY TO THE CONSUMER, ME. WHEN THE BRAKES FAILED, I WAS DRIVING ON A STREET APPROACHING A BUSY INTERSECTION. WITH NO WARNING AT ALL, THE PEDAL WENT TO THE FLOOR AND I HAD NO BRAKES. THE REPAIR FACILITY MECHANIC SAID HE HAS NEVER SEEN A SYSTEM SO BAD. I KEEP THE VEHICLE IN A GARAGE AND HAVE WASHED THE UNDER CARRIAGE IN THE WINTER TO KEEP ROAD SALT FROM ACCUMULATING.

NHTSA ID

11102632

Incident

Mar 15, 2016

Mileage

42,000 mi

TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500. WHILE THE VEHICLE WAS STATIONARY SMOKE APPEARED FROM THE ENGINE IT WAS DIAGNOSED THAT THE FUEL INJECTOR NEEDED TO BE REPLACED ON THE DRIVER'S SIDE THE VEHICLE WAS REPAIRED, BUT THE FAILURE RECURRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 157,000. UPDATED 02/24/17*LJ UPDATED 7/11/18*JB *TR

NHTSA ID

10928316

Incident

Nov 3, 2016

Mileage

157,000 mi

MY 2004 CHEVROLET SILVERADO 2500 HD HAS HAD MULTIPLE BRAKE ISSUES. THE BRAKE LINES AND FUEL LINE HAVE RUSTED OUT. APPROXIMATELY 2 YEARS AGO I HAD BREAK LINE RUST OUT AND THEY WHERE REPLACED. THEY HAVE RUSTED OUT AGAIN.MY TRUCK IS VERY WELL CARED FOR AND IS CLEAN AND NOT DRIVEN OFTEN. I HAVE HAD MULTIPLY CONVERSATIONS WITH GENERAL MOTORS HOTLINE AND HAVE NOT GOT ANYWHERE. I HAVE RESEARCHED THE WEB AND SEE THIS IS A BIG PROBLEM WITH GENERAL MOTORS PRODUCTS.MY TRUCK NOW HAS ABOUT 70,000 MILES AND IS STILL VERY CLEAN AND VERY WELL KEPT. I HOPING SOME ONE COULD LOOK OUT FOR THE CONSUMER AND REQUEST THEY HAVE A RECALL OF THERE PRODUCT BEFORE SOME ONE IS INJURED OR KILLED. *TR

NHTSA ID

10679639

Incident

Jan 23, 2013

Mileage

56,000 mi

WHILE DRIVING IN HEAVY DENVER, COLORADO TRAFFIC LATE AFTERNOON HOURS OF 07/18/2014, MY 2004 CHEVROLET SILVERADO 2500 HD, DURAMAX LLY HAD A "SIGNIFICANT REDUCTION OF ENGINE POWER". GM WAS AWARE OF THIS AS EARLY AS AUGUST 17, 2009, AS PER THEIR BULLETIN # 09-06-04-034. THIS BULLETIN STATES THIS MAY BE CAUSED BY THE FUEL INJECTOR WIRE HARNESS RUBBING AGAINST THE BRACKET AND CHAFING THE WIRE INSULATION. THIS OCCURRED ON MY VEHICLE CAUSING ONE WIRE TO SHORT AGAINST THE BRACKET. THIS IMMEDIATELY SHUT DOWN THE AFFECTED CYLINDER BANK RESULTING IN AN IMMEDIATE REDUCTION OF ENGINE POWER. I FEEL THIS COULD BE A SAFETY CONCERN. FORTUNATELY I WAS ABLE TO GET TO THE SIDE OF THE ROADWAY WITHOUT INCIDENT. I HAVE SENT THREE EMAILS TO [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

10627442

Incident

Jul 18, 2014

Mileage

160,000 mi

BRAKE LINES ALL RUSTED OUT AND FUEL LINES 21,300 MILES ON IT ARE THERE ANY RECALLS OUT YET OR COMING OUT VERY SOON. *TR

NHTSA ID

10547408

Incident

Dec 12, 2012

Mileage

20,000 mi

TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500 HD. THE CONTACT STATED THAT AFTER ENGINE STARTUP, WHITE SMOKE AND HEAVY FUMES EMITTED FROM THE EXHAUST PIPE. THE VEHICLE WAS TAKEN TO THE DEALER WHO CONFIRMED THAT THE FUEL INJECTORS NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS UNKNOWN AND THE CURRENT MILEAGE WAS 208,163.

NHTSA ID

10476698

Incident

Aug 30, 2012

VEHICLE HAS BEEN DIAGNOSED WITH BAD FUEL INJECTORS. SYMPTOMS INCLUDE EXCESSIVE SMOKE AND SMOG TEST FAILURE. MANUFACTURER HAS A 7 YEAR/200,000 MILE WARRANTY ON INJECTORS. MY VEHICLE HAS 121,000 MILES BUT WAS PLACED IN SERVICE 12/2003. MASSIVELY COMMON PROBLEM ON ALL DURAMAX DIESELS. MANUFACTURER ONLY WARRANTIES THE REPAIRED VEHICLES FOR 12 MONTHS OR 12,000 MILES. *TT

NHTSA ID

10445767

Incident

Jan 27, 2012

Mileage

121,625 mi

I HAD MY FUEL INJECTORS REPLACED IN JUNE OF 2010 UNDER AN EXTENDED WARRANTY FROM GM WITH NO OUT OF POCKET COST. 18 MONTHS LATER I AM HAVING THE SAME PROBLEM, FUEL INJECTOR FAILURE AS DIAGNOSED BY A LOCAL CHEVROLET DEALER, BUT BEING TOLD THAT I AM NOW OUT OF WARRANTY AND IT WILL COST $3500+ TO REPAIR. IF THERE IS A DEFECT IN THE INJECTORS, PREVIOUSLY COVERED FOR 7 YEARS/200,000 MILES, WHY ARE THE "NEW IMPROVED" INJECTORS ONLY COMING WITH 12 MONTHS/12,000 MILES. GM HAS A FUEL INJECTOR PROBLEM WITH THEIR DURAMAX DIESELS THAT NEED TO BE ADDRESSED. I HAVE READ HUNDREDS OF POST FROM PEOPLE WITH THE SAME PROBLEMS. AND CHEVROLET IS NOT OFFERING ANY HELP WITH ANY OF THEM. I AM DEALING WITH GM NOW, AND SO FAR HAVE GOTTEN NOWHERE WITH THE ISSUE. *TR

NHTSA ID

10439655

Incident

Jun 17, 2010

Mileage

102,589 mi

TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500. THE CONTACT STATED AFTER THE ENGINE STARTED IT STALLED WITHIN 10 SECONDS. THE VEHICLE WAS TAKEN TO THE DEALER WHO CONFIRMED THE INJECTORS NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS 81,000 AND THE CURRENT MILEAGE WAS 127,000.

NHTSA ID

10436871

Incident

Nov 20, 2008

Mileage

81,000 mi

I WAS BACKING TRUCK INTO DRIVE WAY MOVING ABOUT 5MPH AND APPLIED BRAKES TO PUT TRUCK INTO REVERSE AND BRAKE PEDAL WENT TO FLOOR DID NOT STOP TRUCK. STEEL BRAKE LINE RUPTURED WHERE THE ABS MODULE IS UNDER THE TRUCK RIGHT BELOW DRIVER SEAT. ALL BRAKE LINES LOOK EXTREMELY RUSTY. TRUCK IS A 2004 2500HD CREW CAB 4X4. I BOUGHT BRAND NEW AND IT HAS 47,212 MILES. I PULL A 7000 LBS. CAMPER AND I'M GLAD IT HAPPENED IN MY DRIVEWAY. IN JUNE THE RUBBER GAS LINE FAILED PUMPING 15 GALLONS OF GAS ONTO BOTTOM OF TRUCK AND GROUND ON THE WAY TO WORK (27 MILES). ONCE AGAIN, I WAS LUCKY. I PREFER TO NOT HAVE ANY OTHER STRIKES, TWO IS ENOUGH FOR ME! I HOPE IT DOES NOT TAKE AN INJURY, DEATH, ACCIDENT OR PROPERTY DAMAGE TO GET THE NEEDED ATTENTION THIS VEHICLE NEEDS. *TR

NHTSA ID

10414895

Incident

Jul 23, 2011

Mileage

47,212 mi

THIS HAPPENED IN THE YEAR 2008. EVERYTHING WAS FINE BUT WHEN I WOKE UP THE FOLLOWING DAY, THE SPEEDOMETER WAS POINTING AT 120MPH. IN OTHER WORDS, IT WAS A DIRECT REFLECTION FROM ITS INITIAL POINT, WHICH WAS WHEN IT WAS POINTING AT OR BELOW 0MPH.

NHTSA ID

10408208

Incident

Sep 3, 2008

Mileage

50,000 mi

BOUGHT THE TRUCK IN OCTOBER OF 2009, TOOK TO DEALERSHIP ON 12/17/2009 WITH COMPLAINTS MILEAGE OF 96,764 OF LOW ENGINE POWER, HARD TO START TRUCK,,,,GLOW PLUGS WERE BAD CORRODED PARK NEUTRAL SWITCH, CORROSION ON BRAKE LINES..PAID $ 3,600 IN REPAIRS THEN AROUND LATE SEPTEMBER 9-28-2010TRUCK DIED A FOURWAY INTERSECTION...WAS ALMOST HIT BY A CAR...TOWED TO NEAREST SERVICE FLEET SOURCE...FOUND OUT INJECTORS WERE BAD...WORK WAS STARTED FOR REPAIRS...THEN I FOUND OUT THE GLOW PLUGS...WHICH I PAID FOR ALREADY...AND THE INJECTORS WERE SERVICE BULLETINS...CALLED FLEET TOLD THEM TO STOP REPAIRS...CALLED THE DEALERSHIP...THAT HAD THE TRUCK IN DECEMBER...ASK WHY THEY CHARGED ME FOR THE GLOW PLUGS AND WHY THE DID NOT FIX THE INJECTORS...WHEN IT WAS IN THERE.....DEALERSHIP HUNG UP ON ME...CALLED 1-800-790-5700..SPOKE WITH GM TOLD THEM ABOUT MY CHEVY PROBLEMS...THEY CLAIM THAT MY INJECTORS WOULD NOT BE COVERED...AS IT WAS NOT A DEALERSHIP....FUNNY THING IS THAT FLEET SOURCE IS A CERTIFIED REBUILDER FOR BOSCH, AND SATADYNE BY THE MANUFACTURE FOR THESE PARTS THAT ARE USED IN ALL GM VEHICLES....SO IF YOU TAKE YOUR TRUCK TO A DEALER...THEY GET THEIR PARTS FROM THESE PEOPLE.....GM HAS A HISTORY OF PUTTING ON BULLETINS FOR ITEMS...AND CLAIMING WHEN YOU BRING IN YOUR TRUCK THAT THE PART DOES NOT MEET THE PERIMETER FOR REPLACEMENT....I ABOUT ANOTHER $ 3,200.00 THAT MAKES ABOUT $ 5,0000.00 DOLLARS OF ITEMS THAT PEOPLE HAVE COMPLAINED OUT...HAD RECALLS..SERVICE BULLETINS....NEVER WILL BY ANYTHING THAT GM MAKE AGAIN. *TR

NHTSA ID

10360425

Incident

Sep 28, 2010

Mileage

96,764 mi

2004 CHEVY 2500 HD TRUCK WITH 6.6 DURAMAX DIESEL LOSE FUEL SUCTION. MUST MANUALLY PUMP UP FUEL SYSTEM TO GET TRUCK STARTED. *TR

NHTSA ID

10353580

Incident

Sep 1, 2010

Mileage

17,000 mi

FUEL INJECTORS GO BAD CAUSING ENGINE TO STALL AND LURCH FORWARD WHILE IDLING. THE TRUCK HAS BEEN TO THE DEALER AND HAD THIS PROBLEM REPAIRED 3 TIMES AND IS DOING IT AGAIN *CN *TR

NHTSA ID

10302894

Incident

Jan 10, 2010

TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500 HD. WHILE DRIVING HE SAW SMOKE COMING FROM THE TAIL PIPE, AND THEN HE SMELLED A BURNING ODOR. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION. THE TECHNICIAN CONCLUDED THAT THE THERMOSTATS ARE NOT ALLOWING THE VEHICLE TO ACHIEVE OPERATING TEMPERATURE AND INJECTORS 5, 6, 1 ARE DEFECTIVE. THE REPAIR WILL BE PERFORMED AT THE OWNERS EXPENSE. THE FAILURE MILEAGE WAS 102000. THE CURRENT MILEAGE WAS 103000.

NHTSA ID

10289961

Incident

Oct 15, 2009

Mileage

102,000 mi

FUEL GAUGE AT FILL UP WENT PAST FULL AND COMPLETELY CLOCK WISE...GAUGE READING IS ALL OVER THE PLACE EVERYTIME I START ENGINE. VEHICLE HAS 59,000 MILES. I HAVE TO READ MY "RANGE" READING, (UNCERTAIN OF ACCURACY)TO APPROXIMATE FUEL IN DIESEL TANK. *TR

NHTSA ID

10256687

Incident

Nov 20, 2008

Mileage

59,000 mi

AT APPROX 65,000 MILES MY SPEEDOMETER STOPPED WORKING ALONG WITH OTHER GAUGES IN THE INSTRUMENT PANEL. GM REFUSED TO FIX THE PROBLEM. WHEN I HAD 80,000 MILES GM OFFERED TO FIX THE DEFECT ONLY ON VEHICLES WITH LESS THAN 70,000 MILES. THEY REFUSED TO CORRECT THE DEFECT ON MY VEHICLE. THE DEALER ESTIMATES THE COST TO FIX THIS DEFECT AT APPROX $450.00 I NOW HAVE APPROX 105,000 MILES AND CONTINUE TO DRIVE WITHOUT A WORKING SPEEDOMETER. THIS VEHICLE AND MANY WITH THIS SAME DEFECT IS USED FOR TOWING. GM HAS PUT PROFIT AHEAD OF SAFETY AND CUSTOMER SATISFACTION. THE NTSB HAS CONTINUED TO ALLOW THOUSANDS OF VEHICLES TO OPERATE UNSAFELY WITH THIS WELL KNOWN AND DOCUMENTED DEFECT BY FAILING TO FORCE GM TO RECALL THESE VEHICLES MANY OF WHICH WERE STILL BEING MANUFACTURE AFTER THE DEFECT WAS DISCOVERED. *TR

NHTSA ID

10239450

Incident

Nov 12, 2007

Mileage

65,000 mi

TL*THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500 4X4 DIESEL. WHILE DRIVING VARIOUS SPEEDS, THE VEHICLE WOULD MISFIRE. THE NEXT MISFIRE WOULD RECUR 45 MINUTES LATER, AND THE THIRD MISFIRE WOULD NORMALLY RECUR AN HOUR AFTERWARDS. THE FAILURE WAS INTERMITTENT. THE CONTACT COULD NOT DRIVE OVER 25 MPH AND THE VEHICLE CONSTANTLY JERKED. IN JANUARY OF 2008, SHE TOOK HER VEHICLE TO THE DEALER AND THEY REPLACED TWO FUEL INJECTORS. ON APRIL 2, 2008, THE DEALER REPLACED 8 FUEL INJECTORS. AFTER THE MOST RECENT FAILURE, THE CONTACT TOOK THE VEHICLE TO THE DEALER FOR A DIAGNOSTIC. THEY COULD NOT LOCATE ANY FAILURES. THE FAILURE MILEAGE WAS 65,000 AND CURRENT MILEAGE WAS 97,000.

NHTSA ID

10230855

Incident

Jan 5, 2008

Mileage

65,000 mi

TL*THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500 HD. WHILE DRIVING 65 MPH, HE SAW SMOKE COMING FROM THE TAIL PIPE. THE DEALER STATED THAT THE INJECTORS CAUSED THE FAILURE. AS OF JANUARY 11, 2008, THE DEALER HAD NOT REPAIRED THE VEHICLE. THE FAILURE MILEAGE 87,900 AND CURRENT MILEAGE WAS 88,546.

NHTSA ID

10214552

Incident

Dec 1, 2007

Mileage

87,900 mi

TL*THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500 HD. WHILE DRIVING UPHILL AT 55 MPH, THE ENGINE FAILED WITHOUT WARNING. THE CONTACT WAS ABLE TO COAST TO THE SIDE OF THE ROAD. HE REPRIMED THE FUEL FILTER AND THE VEHICLE DROVE APPROXIMATELY A MILE AND A HALF BEFORE IT SHUT OFF AGAIN. HE HAD TO REPRIME THE FILTER AGAIN. THE CONTACT PULLED OVER TO ALLOW THE VEHICLE TO COOL OFF. THE VEHICLE WAS TAKEN TO A SERVICE STATION AND THE MECHANIC SPOKE WITH CHEVROLET, WHO WAS NOT AWARE OF ANY RECALLS. THE CURRENT AND FAILURE MILEAGES WERE 95,000. *UPDATED 12/27/07 *LJ UPDATED 12/12/07 *TR

NHTSA ID

10204551

Incident

Sep 30, 2007

Mileage

95,000 mi

2004 CHEVY SILVERADO 2500 HD WITH FUEL INJECTORS PROBLEMS CUSTOMER STATES THAT THEY HAVE HAD THE FUEL INJECTORS REPLACED THREE TIMES AND WANTS GM TO STAND BEHIND IT'S PRODUCT**NAR**CC ON 8/01/06 THE CHECK ENGINE LIGHT ILLUMINATED AND THE TRUCK BEGAN TO EMIT WHITE SMOKE. THE CONSUMER TOOK THE VEHICLE TO THE DEALER IT WAS NOTED THAT THE FUEL INJECTORS HAD HIGH BALANCE RATES SO ALL WERE REPLACED. IN APRIL THE GAUGES ALL SHUT DOWN AND THE TRUCK STOPPED RUNNING IN THE DESERT IN 100 DEGREE WEATHER AND WERE INFORMED BY A SECOND DEALER FUEL INJECTORS NEEDED TO BE REPLACED YET AGAIN. THE CONSUMER STATED WAS PREPARING FOR A TRIP DECIDED TO TAKE THE VEHICLE BACK INTO THE DEALER TO HAVE THE TRUCK CHECKED AND BEHOLD A THIRD TIME THE FUEL INJECTORS NEEDED TO BE REPLACED. THE CONSUMER STATED WOULD LIKE VEHICLE FIXED. *TR

NHTSA ID

10199129

Incident

Jul 1, 2007

Mileage

66,271 mi

INJECTORS NUMBER 2 AND 7 LOOSE CONNECTOR AND OIL PUMP RUBBING THROUGH TRANSFER CASE ON CHEVY SILVERADO HD2500 TRAVELING DOWN THE HIGHWAY PULLING A HORSE TRAILER THE TRUCK WENT INTO LIMP MODE AND WOULD NOT KEEP UP WITH HIGHWAY SPEED. HAD TO PULL OVER ON AN INTERSTATE AND ATTEMPT A QUICK REPAIR ALONG THE ROAD. TRANSFER CASE HAS NOT YET CAUSED A PROBLEM, HOWEVER, THE ALUMINUM RESIDUES IN THE CASE OIN ARE VERY HIGH AND WHEN PUMP GOES THROUGH CASE ALL OIL WILL BE LOST AND THE VEHICLE WILL STOP. *NM

NHTSA ID

10171687

Incident

May 26, 2006

Mileage

25,000 mi

DT*: THE CONTACT STATED AFTER PARKING IN THE DRIVEWAY A GASOLINE LEAK WAS OBSERVED COMING FROM THE GAS TANK. THE VEHICLE WAS TAKEN TO DEALERSHIP WHO DETERMINED THE GAS TANK MUST BE REPLACED. THE CONTACT EXPRESSED THAT THE MANUFACTURER SHOULD BE RESPONSIBLE FOR THE TANK REPLACEMENT IN A VEHICLE WITH ONLY 58619 MILES.

NHTSA ID

10167255

Incident

Aug 30, 2006

Mileage

58,619 mi

I WAS DRIVING DOWN THE FREEWAY GOING 70 MPH ON MY WAY TO WORK DURING RUSH HOUR TRAFFIC IN THE FAST LANE. ALL OF A SUDDEN I LOST POWER AND THE TRUCK STARTED SLOWING DOWN QUICKLY. I IMMEDIATELY HAD TO TRY TO GET OVER AND GET OFF THE FREEWAY SO THAT I WOULD NOT GET RUN OVER, WHICH IS NOT AN EASY THING TO HAVE A VEHICLE ON THE FREEWAY DURING RUSH HOUR THAT WILL NOT GO OVER 15 MPH. THIS IS NOT VERY SAFE AND I COULD HAVE EASILY HAVE CAUSED AN ACCIDENT BY CARS TRYING TO SWERVE AROUND MY VEHICLE THAT WOULD NOT ACCELERATE. THE PROBLEM WAS THE #7 FUEL INJECTOR CONNECTOR, WHICH HAS BEEN REPLACED AND I DO HAVE THE OLD PART. I AM NOT THE ONLY ONE THIS HAS HAPPENED TO AND THIS SHOULD NOT BE HAPPENING TO A TWO YEAR OLD VEHICLE. WHEN THIS PART BREAKS, I FEEL PEOPLE ARE AT RISK AND THIS SHOULD BE TAKEN CARE OF. *JB

NHTSA ID

10166281

Incident

Jul 18, 2006

Mileage

69,407 mi