GMC SIERRA 2500 · model year

2004 GMC SIERRA 2500

175 NHTSA complaints, 4 crash reports, and 4 active recalls for this specific cohort.

NHTSA overall rating

Not crash-tested

New Car Assessment Program

The 2004GMCSIERRA 2500 carries 175 consumer safety complaints in NHTSA's Office of Defects Investigation database for this specific model-year cohort. Within that volume, owners reported 4 crashes, 4 fires, 5 injuries, and 1 fatality. No NCAP 5-star crash-test rating is available for this model year in the federal database.

Component-level analysis is where model-year complaints become actionable: the top complaint category for the 2004 SIERRA 2500 is service brakes with 33 filings, followed by electrical system: instrument cluster/panel (27) and electrical system (20). Concentration in one or two component groups is the classic signature of a systemic defect; a flat distribution usually reflects normal aging, warranty complaints, or isolated build-plant variability. This model year has 4 active recall campaigns, which means the manufacturer is obligated to remedy the covered defect at no charge for the life of the vehicle, the full NHTSA campaign numbers are listed below.

NHTSA currently has 2 investigation files overlapping the 2004 SIERRA 2500. Owners comparing this cohort against neighboring years should pair the counters above with the complaint-by-year trend on the parent model page, a spike in a single year often tracks to a platform refresh, a new transmission supplier, or an updated ECU calibration. Use the related-complaint feed below to read raw owner narratives before deciding whether any pattern here affects your specific use case.

175
Complaints
4
Crashes
4
Fires
5
Injuries
1
Deaths

Total Complaints

175 filings

Crashes Reported

4 reports

Source

NHTSA ODI

Federal complaints database

Complaints vs. fleet median (215)

At or below the fleet median complaint volume.

Complaints by Component

ComponentCount
SERVICE BRAKES33
ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL27
ELECTRICAL SYSTEM20
SERVICE BRAKES, HYDRAULIC16
ENGINE9
FUEL SYSTEM, DIESEL5
STEERING5
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP3
POWER TRAIN:AUTOMATIC TRANSMISSION3
TIRES3
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM3
ENGINE AND ENGINE COOLING2
AIR BAGS2
POWER TRAIN:AXLE ASSEMBLY:AXLE SHAFT:SEAL2
VEHICLE SPEED CONTROL2

Recalls (4)

04V56200026/11/2004

EQUIPMENT ADAPTIVE/MOBILITY

ON CERTAIN VANS EQUIPPED WITH SURE-LOK WHEELCHAIR SECUREMENT SYSTEMS, THE SPROCKET TEETH OF THE RETRACTOR ASSEMBLY IS OUT OF ALIGNMENT.

06E04300019/05/2006

FUEL SYSTEM, GASOLINE

CERTAIN REPLACEMENT FUEL FILTERS, FRAM BRAND NAME P/N G3727, WITH DATE CODES X52911 THROUGH X60801 SEQUENTIALLY OR X600141 AND A MEXICO COUNTRY OR ORIGIN MARKING ON THE FUEL FILTER HOUSING MANUFACTURED FROM OCTOBER 18, 2005, THROUGH MARCH 21, 2006, SOLD FOR USE ON THE VEHICLES LISTED ABOVE AND ON CE

06E05000006/06/2006

SERVICE BRAKES, AIR

CERTAIN FEDERAL-MOGUL NATIONAL AND CARQUEST AFTERMARKET HUB ASSEMBLIES, P/N 515058, SOLD FOR USE ON 2001-2006 GENERAL MOTORS 1500 AND 2500 4WD TRUCKS. ON THE SUBJECT HUB ASSEMBLIES, THE ABS SENSOR CORD DEPARTS FROM THE HUB ASSEMBLY AT A 90 DEGREE ANGLE. AS A RESULT, THERE IS A FIT ISSUE WITH THE B

06E01000001/02/2006

STEERING

CERTAIN FABTECH AFTERMARKET REPLACEMENT PITMAN ARMS, P/NOS. FTS71000 AND FTS71001, INSTALLED FOR USE ON CERTAIN 2001-2006 GM C/K 2500 PICK UP TRUCKS AND SPORT UTILITY VEHICLES. THE PIN LOCATED INSIDE THE PITMAN ARM CAN SHEAR OFF DUE TO A REVERSE BENDING FATIGUE CONDITION, RESULTING IN A TOTAL LOSS

Recent Complaints

20211130SERVICE BRAKES

Brakes lines failed under truck do to rusted out lines

20210416SERVICE BRAKES

EMERGENCY BRAKES DON'T ENGAGE

20200104SERVICE BRAKES

DURING COLD MORNINGS (WISCONSIN) I START MY TRUCK AND I HAVE NO POWER STEERING AND SOFT BRAKES. IT IS MY UNDERSTANDING THAT THE POWER STEERING RUNS THE BRAKE BOOST. ALSO, IT IS MY UNDERSTANDING THAT THERE IS A SERVICE BULLETIN THAT SAYS THAT THE POWER STEERING FLUID SHOULD BE REPLACED WITH LOW/COLD TEMP FLUID. MY CONCERN IS WHAT HAPPENS IF I LOSE POWER STEERING AND BRAKES WHILE I AM DRIVING.

Mileage: 158,500

20200104STEERING

DURING COLD MORNINGS (WISCONSIN) I START MY TRUCK AND I HAVE NO POWER STEERING AND SOFT BRAKES. IT IS MY UNDERSTANDING THAT THE POWER STEERING RUNS THE BRAKE BOOST. ALSO, IT IS MY UNDERSTANDING THAT THERE IS A SERVICE BULLETIN THAT SAYS THAT THE POWER STEERING FLUID SHOULD BE REPLACED WITH LOW/COLD TEMP FLUID. MY CONCERN IS WHAT HAPPENS IF I LOSE POWER STEERING AND BRAKES WHILE I AM DRIVING.

Mileage: 158,500

20181209ENGINE

WHILE DRIVING OVER 50MPH ON THE HIGHWAY I GET A VIOLENT SHAKING IN THE ENGINE AND THE STEERING WHEEL SHAKES BAKE AND FORTH. THE ENGINE SOUND VERY LOUD WHILE ITS DOING THIS. IT ONLY OCCURS WHEN I AM AT HIGHWAY SPEEDS.

Mileage: 49,000

20181127ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:MANIFOLD/HEADER/MUFFLER/TAIL PIPE

TL* THE CONTACT OWNS A 2004 GMC SIERRA 2500. WHILE DRIVING APPROXIMATELY 45 MPH, THE CONTACT NOTICED A LOT OF WHITE SMOKE EMERGING FROM THE TAIL PIPE. THE VEHICLE WAS PREVIOUSLY REPAIRED UNDER WARRANTY BY GWATNEY BUICK GMC (5700 LANDERS RD, NORTH LITTLE ROCK, AR 72117) FOR THE SAME FAILURE AS LISTED IN AN UNKNOWN TECHNICAL SERVICE BULLETIN REGARDING THE FUEL INJECTORS. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED FOR THE RECENT FAILURE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 90,000.

Mileage: 90,000

20181026ENGINE

EXHAUST MANIFOLD BOLTS BROKEN

Mileage: 105,000

20180329SERVICE BRAKES

PULLING OUT OF A PARKING LOT, LOST BRAKES. STEEL BRAKE LINES BY FUEL TANK, LET GO CAUSING TRUCK TO LOOSE BRAKES

Mileage: 63,000

20170923ELECTRICAL SYSTEM

THE INSTRUMENT PANEL CLUSTER GAUGES DON'T ALWAYS WORK. WE WERE ON FREEWAY WHEN WE NOTICED SPEEDOMETER HAD FAILED AS WELL AS FUEL GAUGE , TEMP GAUGE ALL GAUGES INOPERATIVE. THIS IS THIRD TIME CLUSTER PANEL IS BEING REPLACED; FIRST TWO UNDER WARRANTY THIRD TIME WE HAD TO PAY $204.

Mileage: 111,000

20170822SERVICE BRAKES

I WAS TRAVELING SOUTH ON I-75 HIGHWAY ABOUT 70 MPH, IN MOTION, IN NORTHERN MICHIGAN AND HAD TO STOP FAST WHEN AN ACCIDENT OCCURRED IN FRONT OF ME. I SLAMMED/MASHED MY FOOT ON THE BRAKE PEDAL ONLY TO FEEL IT FALL TO THE FLOOR, THE METAL HYDRAULIC LINE FAILED AND I NOW HAVE NO BRAKES AT ALL!! I BEGAN TO PRESS ON THE PARKING BRAKE AND DOWN SHIFT THE TRANSMISSION TO ASSIST IN THE SLOWING OF THE VEHICLE. I ALSO STEERED AROUND THE STOPPED CARS INTO THE SIDE AND DITCH OF THE ROAD. I LUCKILY HAD THE RIGHT REACTIONS BUT NOT ALL PEOPLE DO OR CANNOT ACT AS FAST. THIS IS A DANGEROUS ISSUE WITH THIS GMC SIERRA 2004. PLEASE HAVE IT RECALLED. I HAD TO HAVE THE REPAIR SHOP REPLACE ALL THE METAL BRAKE LINES AS THEY WERE CORRODED. I HAVE NEVER HAD A VEHICLE FAIL ITS BRAKE LINES LIKE THIS. MY VEHICLE ONLY HAS 48,000 MILES ON IT AND IS GARAGE KEPT SUPER CLEAN.

Mileage: 48,000

20170210SERVICE BRAKES

MY VEHICLE HAD BRAKE LINES REPLACE TWO TIMES WITH LESS THAN 65,000 MILES BECAUSE BREAKS STOP WORKING. FUEL LINE REPLACED UNDER 55,000 MILES BECAUSE IT MADE CHECK ENGINE LIGHT COME ON SPEEDOMETER ERRATIC,OIL PRESSURE GAUGE HIGH AND LOW,FUEL GAUGE ERRATIC UNDER 65,000 MILES. LOUD NOISE FROM ENGINE SERVICE TECHNICIAN REPORTED THE EXHAUST MANIFOLD BOLTS HAS BROKEN TO CALL A WHITE SMOKE FROM THE MOTOR. EVERYTHING HAPPENED WITH CONSIDER TO BE LOW MILEAGE IN TALKING TO GM THEY DON'T CARE BECAUSE ENOUGH REPORT HAS NOT BEEN MADE.

Mileage: 45,000

20170210ELECTRICAL SYSTEM

MY VEHICLE HAD BRAKE LINES REPLACE TWO TIMES WITH LESS THAN 65,000 MILES BECAUSE BREAKS STOP WORKING. FUEL LINE REPLACED UNDER 55,000 MILES BECAUSE IT MADE CHECK ENGINE LIGHT COME ON SPEEDOMETER ERRATIC,OIL PRESSURE GAUGE HIGH AND LOW,FUEL GAUGE ERRATIC UNDER 65,000 MILES. LOUD NOISE FROM ENGINE SERVICE TECHNICIAN REPORTED THE EXHAUST MANIFOLD BOLTS HAS BROKEN TO CALL A WHITE SMOKE FROM THE MOTOR. EVERYTHING HAPPENED WITH CONSIDER TO BE LOW MILEAGE IN TALKING TO GM THEY DON'T CARE BECAUSE ENOUGH REPORT HAS NOT BEEN MADE.

Mileage: 45,000

20170210ENGINE

MY VEHICLE HAD BRAKE LINES REPLACE TWO TIMES WITH LESS THAN 65,000 MILES BECAUSE BREAKS STOP WORKING. FUEL LINE REPLACED UNDER 55,000 MILES BECAUSE IT MADE CHECK ENGINE LIGHT COME ON SPEEDOMETER ERRATIC,OIL PRESSURE GAUGE HIGH AND LOW,FUEL GAUGE ERRATIC UNDER 65,000 MILES. LOUD NOISE FROM ENGINE SERVICE TECHNICIAN REPORTED THE EXHAUST MANIFOLD BOLTS HAS BROKEN TO CALL A WHITE SMOKE FROM THE MOTOR. EVERYTHING HAPPENED WITH CONSIDER TO BE LOW MILEAGE IN TALKING TO GM THEY DON'T CARE BECAUSE ENOUGH REPORT HAS NOT BEEN MADE.

Mileage: 45,000

20161130ENGINE

TL* THE CONTACT OWNS A 2004 GMC SIERRA 2500. THE CONTACT STATED THAT THE VEHICLE HAD A MASSIVE OIL LEAK. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE FUEL INJECTORS WERE DEFECTIVE, WHICH FILLED THE CRANKCASE FULL OF FUEL AND WAS A KNOWN ISSUE. THE VEHICLE WOULD HAVE BEEN REPAIRED PER AN EXTENDED WARRANTY; HOWEVER, IT FELL OUTSIDE OF THE PARAMETERS OF THE EXTENDED WARRANTY, INCREASING THE RISK OF AN ENGINE COMPARTMENT FIRE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 112,000.

Mileage: 112,000

20161130FUEL/PROPULSION SYSTEM

TL* THE CONTACT OWNS A 2004 GMC SIERRA 2500. THE CONTACT STATED THAT THE VEHICLE HAD A MASSIVE OIL LEAK. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE FUEL INJECTORS WERE DEFECTIVE, WHICH FILLED THE CRANKCASE FULL OF FUEL AND WAS A KNOWN ISSUE. THE VEHICLE WOULD HAVE BEEN REPAIRED PER AN EXTENDED WARRANTY; HOWEVER, IT FELL OUTSIDE OF THE PARAMETERS OF THE EXTENDED WARRANTY, INCREASING THE RISK OF AN ENGINE COMPARTMENT FIRE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 112,000.

Mileage: 112,000

20160318SERVICE BRAKES

TL* THE CONTACT OWNS A 2004 GMC SIERRA 2500 HD. WHILE DRIVING 10 MPH, THE BRAKES FAILED WITHOUT WARNING. IT WAS DIAGNOSED THAT ALL THE BRAKE LINES NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 176,395.

Mileage: 176,395

20160316SERVICE BRAKES

IN THE PAST THREE MONTHS THE FUEL LINES NEEDED REPLACEMENT AS THEY HAD RUSTED SO BADLY THAT A LEAK FORMED. YESTERDAY WHILE PULLING MY 10,000 POUND BOAT, MY BRAKES SUDDENLY FAILED BECAUSE OF A LEAK IN THE LINE BETWEEN THE ABS BOX AND THE RIGHT FRONT WHEEL. THE CATASTROPHIC FAILURE NEARLY CAUSED ME TO LOSE CONTROL OF MY VEHICLE AND BOAT. I WAS ABLE TO DOWNSHIFT AND USE BY EMERGENCY BRAKE TO BRING THE RIG TO A STOP.

Mileage: 107,900

20160316FUEL/PROPULSION SYSTEM

IN THE PAST THREE MONTHS THE FUEL LINES NEEDED REPLACEMENT AS THEY HAD RUSTED SO BADLY THAT A LEAK FORMED. YESTERDAY WHILE PULLING MY 10,000 POUND BOAT, MY BRAKES SUDDENLY FAILED BECAUSE OF A LEAK IN THE LINE BETWEEN THE ABS BOX AND THE RIGHT FRONT WHEEL. THE CATASTROPHIC FAILURE NEARLY CAUSED ME TO LOSE CONTROL OF MY VEHICLE AND BOAT. I WAS ABLE TO DOWNSHIFT AND USE BY EMERGENCY BRAKE TO BRING THE RIG TO A STOP.

Mileage: 107,900

20160304SERVICE BRAKES

I LIVE IN SOUTH EAST MA. WERE SAULT IS USE ALWAYS AND IT HAS ROTTED MY BRAKE LINES AT THE ABS CONTROLL A LINE LET GO ON MY TRUCK WITH FAMILY AND MY GRAND BABIES I AM A HEAVY TRUCK OPERATOR WITH A CDL SO I KNOW NOT TO PANIC I GOT MY TRUCK STOPPED WITHOUT A CRASH BUT IF MY WIFE WAS DRIVEING OR MY YOUNG DAUGHTER THEY WOULDNT BE SO LUCKY WE IN THE SAULTING STATES SHOULD HAVE STANELESS STEAL FOR SAFTY CANT BE TO MUCH TO ASK FOR YOUNG LIFES AT STAKE OR PEOPLE WHO PANIC WHAT SHOULD I DO AT THE TIME I WAS IN THE CITY OF TAUNTON I WAS COMING TO A HEAVILY TRAVELED STREET IN RUSH HOUR TRAFIC THE BRAKE LINE TO REAR BRAKES FALLED BECAUSE OF ROT ON INSPION I SEE THEY ARE ALL ROTTING AND NEED TO BE REPAIRED I DONT HAVE BODY ROT OR FRAME ROT OF ANY KIND ALWAYS CAR WASH AFTER STORMS ON NICE DAYS.

Mileage: 185,000

20150807SERVICE BRAKES

TL* THE CONTACT OWNS A 2004 GMC 2500. THE CONTACT STATED THAT THE EMERGENCY BRAKE WAS INOPERABLE. THE CONTACT MENTIONED THAT THE PARKING BRAKE WAS DEPRESSED AND AN ABNORMAL NOISE EMITTED FROM THE UNDER CARRIAGE OF THE VEHICLE. THE CONTACT BELIEVED THAT THE PARKING BRAKE CABLE WAS FRACTURED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 197,000.

Mileage: 197,000

Compare 2004GMCSIERRA 2500 to Similar Vehicles

NHTSA Investigations

Frequently Asked Questions

How many complaints does the 2004 GMC SIERRA 2500 have?
The 2004 GMC SIERRA 2500 has 175 NHTSA complaints, 4 crashes, 4 fires, 5 injuries, and 1 deaths reported.
Are there any recalls for the 2004 GMC SIERRA 2500?
Yes, the 2004 GMC SIERRA 2500 has 4 recall(s). The most common affected component is EQUIPMENT ADAPTIVE/MOBILITY. Recalls are issued by NHTSA and manufacturers must provide a free remedy.
What are the most common problems with the 2004 GMC SIERRA 2500?
The most-complained component for the 2004 GMC SIERRA 2500 is SERVICE BRAKES with 33 complaints. Other frequently reported areas include ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL and ELECTRICAL SYSTEM.
Is the 2004 GMC SIERRA 2500 safe to buy?
Review the complaint history, crash and fire reports, safety ratings, and recall status on this page to make an informed decision. No NHTSA crash test rating is available for this model year. Compare with other model years using the links above.
Where does this data come from?
All complaint, recall, and safety rating data is sourced from the National Highway Traffic Safety Administration (NHTSA). Complaints are filed by vehicle owners through NHTSA's Office of Defects Investigation.

Vehicle Safety Guides

Data as of 2025. Sources: NHTSA Office of Defects Investigation (ODI) complaints database, NHTSA recall campaign API, NHTSA NCAP crash-test ratings, and NHTSA FARS for fatality cross-reference.