Total Complaints
29 filings
GMC SIERRA 3500 · model year
29 NHTSA complaints, and 1 active recall for this specific cohort.
NHTSA overall rating
Not crash-tested
New Car Assessment Program
The 2004GMCSIERRA 3500 carries 29 consumer safety complaints in NHTSA's Office of Defects Investigation database for this specific model-year cohort. Within that volume, owners reported 0 crashes, 2 fires, 0 injuries, and 0 fatalities. 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 3500 is service brakes with 8 filings, followed by electrical system (3) and service brakes, hydraulic (3). 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 1 active recall campaign, 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 3500. 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.
Total Complaints
29 filings
Crashes Reported
0 reports
Source
NHTSA ODI
Federal complaints database
At or below the fleet median complaint volume.
| Component | Count |
|---|---|
| SERVICE BRAKES | 8 |
| ELECTRICAL SYSTEM | 3 |
| SERVICE BRAKES, HYDRAULIC | 3 |
| FUEL SYSTEM, DIESEL | 2 |
| ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL | 2 |
| STRUCTURE:FRAME AND MEMBERS:UNDERBODY SHIELDS | 1 |
| POWER TRAIN:DRIVELINE:CENTER SUPPORT BEARING | 1 |
| POWER TRAIN:TRANSFER CASE (4-WHEEL DRIVE) | 1 |
| STEERING:HYDRAULIC POWER ASSIST SYSTEM | 1 |
| SERVICE BRAKES, HYDRAULIC:POWER ASSIST | 1 |
| SERVICE BRAKES, ELECTRIC | 1 |
| TIRES:SIDEWALL | 1 |
| FUEL SYSTEM, GASOLINE:FUEL INJECTION SYSTEM:INJECTORS | 1 |
| STEERING | 1 |
| FUEL SYSTEM, GASOLINE | 1 |
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
The fan for the heater doesnt work on all speeds properly, stopped working entirely
WHILE PULLING A CAMPER-TRAILER, I APPLIED THE BRAKES AND THE PEDAL WENT COMPLETELY TO THE FLOOR. I WAS ABLE TO STOP UTILIZING THE BRAKES ON THE TRAILER. I WAS ONLY A SHORT DISTANCE FROM HOME AND I WAS ABLE TO GET THE TRAILER BACK, KEEPING THE TRANSMISSION IN 1ST GEAR AND THE TRAILER BRAKES. I TOOK THE TRUCK TO A CHEVY DEALER THAT WAS JUST A VERY SHORT DISTANCE UTILIZING THE GEARS AND THE EMERGENCY BRAKE. UPON INSPECTION, THE DEALER FOUND AT LEAST TWO LOCATIONS WHERE THE BRAKE LINE HAD RUSTED THROUGH. HE RECOMMENDED TO REPLACE ALL BRAKE LINES WITH A LINE THAT WAS CORROSION RESISTANT. THE REPAIR WAS JUST UNDER $2000. I HAVE NOT CONTACTED GMC SINCE THE TRUCK HAS 74,000 MILES AND IS OUT OF ALL WARRANTIES. *TR
Mileage: 74,000
I WAS TRAVELING ON THE INTERSTATE TOWING A 5TH WHEEL TRAILER AND TRAFFIC CAME TO AN ABRUPT STOP. I APPLIED MY BRAKES AND HAD BRAKES THAN THE PEDAL WENT TO THE FLOOR AND I LOST BRAKING POWER. I LET OFF THE BRAKES AND REAPPLIED THE BRAKES AND THE PEDAL WENT TO THE FLOOR WITH LOW BREAKING AFFECT. I PULLED THE TRUCK OVER AND FOUND BRAKE FLUID COMING OUT FROM ABOVE THE GAS TANK. I CAREFULLY TOOK THE TRUCK OFF AT THE NEXT EXIT USING MY TRAILER BRAKES TO STOP THE VEHICLE. I TOOK THE TRUCK TO THE FIRST SERVICE STATION THAT I SAW AND HAD THEM LOOK AT IT. THEY FOUND THAT THE REAR BRAKE LINE HAD CORRODED AT A CLIP ABOVE THE FRAME RAIL ABOVE THE GAS TANK AND ADVISED ME THAT THEY WOULD HAVE TO REPLACE THE REAR BRAKE LINE. UNFORTUNATELY I WAS STUCK AWAY FROM MY TOOLS AND SERVICE SHOPS THAT I USE AND WAS STUCK BEING GOUGED BY THE SERVICE CENTER THAT I WAS ABLE TO GET TO FOR A REPAIR. AFTER I RETURNED HOME FROM VACATION I QUESTIONED THE MGT OF THE SERVICE CENTER ABOUT THE BILL. THEY CHECKED WITH THE
Mileage: 131,883
BRAKE LINE RUSTED OUT AND FAILED IN TWO SPOTS IN THE LAST MONTH. *TR
Mileage: 164,000
THIS PAST WEEK, AS I WAS DRIVING TO GET GAS FOR OUR CAMPING TRIP, THE BRAKE PEDAL WENT STRAIGHT TO THE FLOOR WITH NO WARNING. I WAS ABLE TO GET THE DUALLY SLOWED DOWN WITHOUT INCIDENT, BUT WAS IT EVER CLOSE. AFTER GETTING THE TRUCK BACK TO MY HOUSE, I BEGAN INVESTIGATING THE ISSUE AS I SAW NO LEAK AND THE RESERVOIR WAS NEAR FULL. I SAW ONLINE THAT THIS SEEMS TO BE A GM ISSUE WITH A FEW YEARS OF TRUCKS IN MY AGE BRACKET. I CLIMBED UP UNDER THE TRUCK AND FOUND THE LINES TO BE SHOT. NOT ONE WITH A RUST HOLE, BUT ALL OF THEM CORRODED FROM ONE END TO THE OTHER. I KNOW THE TRUCK IS 8 YEARS OLD, BUT IT SITS MOST THE TIME AND ALMOST ALWAYS THROUGH THE WINTER. I HAVE ONLY HAD ONE OTHER CAR IN 30 YEARS THAT HAD A BRAKE LINE RUST. IT SHOULD NOT BE HAPPENING IN THIS HIGH END OF A VEHICLE. MY DAD BOUGHT THE MATCHING TRUCK. HIS SITS WINTERS IN THE BARN AND ONLY HAS 50K ON IT. I WILL CHECK IT THIS WEEKEND. *JS
Mileage: 105,000
BRAKES FAILED DUE TO A SUDDEN BRAKE LINE FAILURE. THERE HAD BEEN NO PRIOR FLUID LEAKS. THE REAR METAL BRAKE LINE UNDER THE BED RUSTED AT A CLAMP IN FRONT OF THE FUEL TANK. AS I HAVE LOOKED FURTHER INTO THIS I HAVE SEVERAL FRIENDS THAT HAVE HAD THIS PROBLEM AND SEVERAL SHOPS SAID THAT THEY SAW THIS OFTEN WITH THESE VEHICLES ALL FAILING IN THE SAME AREA. *TR
Mileage: 131,883
I PICKED MY STEPDAUGHTER AT SCHOOL AND AT THE STOPLIGHT TO LEAVE THE SCHOOL THERE WERE NO BRAKES. I USED THE CURB TO SLOW THE TRUCK ENOUGH TO THE LIGHTS TO CHANGE. IT WAS NOT A BUSY TIME AND STUDENTS WERE NOT PRESENT OTHERWISE THIS WOULD HAVE BEEN A DISASTER. I DROVE THE TRUCK HOME WITH FLASHERS VERY SLOWLY HOME ON A BACK ROAD DOWNSHIFTING AND RELYING IN THE ALLISON TRANSMISSION. WHEN I REACHED HOME THE LIGHT CAME ON TO SERVICE BRAKES. THAT WAS OBVIOUS ALREADY. THIS IS A 1 TON DUALLY THAT USUALLY HAULS SKID LOADS, PAVING BRICKS, ETC. I COULD NOT IMAGINE WHAT WOULD HAVE HAPPENED IF THE BRAKE LINES BLEW DURING THIS TIME. THERE IS A SMALL RUSTED PIN SIZED WHOLE IN THE FRONT BRAKE LINE THAT RUNS ON TOP OF THE TRUCK FRAME. I STILL HAVE BRAKE FLUID IN THE RESERVOIR, BUT NOT ENOUGH TO STOP THE TRUCK. THERE WAS NOT WARNING AND THOSE LINES ARE TUCKED UP ON THE FRAME OUT OF SITE FOR INSPECTION. THIS INCIDENT WENT TO FINE TO DISASTER IMMEDIATELY. WHAT WOULD HAVE HAPPENED IF THIS VEHI
Mileage: 60,004
APPROACHING A STOP. WHEN THE BRAKES WERE APPLIED, THE BRAKE PEDAL DROPPED ALMOST COMPLETELY TO THE FLOOR AND STOPPING WAS EXTREMELY DIFFICULT. DISCOVERED THAT THE BRAKE LINES WHICH RUN ALONG THE FRAME BEHIND THE DRIVER SIDE FRONT WHEEL HAD CORRODED TO THE POINT WHERE ONE OF THE LINES FAILED AND BLEW OPEN. THE LINES ARE CLAMPED AGAINST THE FRAME IN THIS LOCATION, AND ALL THE 4 LINES AT THE BRACKET APPEAR EXTREMELY CORRODED. *TR
Mileage: 133,000
ON HIGHWAY MULTI-LANE, HEAVY TRAFFIC AHEAD, SUDDENLY SLOWED AND A LOT OF LANE CHANGING GOING ON AS SOME DEBRIS WAS EJECTED FROM TRUCK ONTO ROADWAY. APPLIED BRAKES, APPLICATION HAD LITTLE EFFECT. STOOD ON THE BRAKES, BUTT OUT OF THE SEAT STANDING ON THE BRAKES, TRUCK VEERED OFF TO RIGHT SEVERELY WHILE ANT LOCK PULSED. FORTUNATELY TRAFFIC GOT OUT OF THE WAY AND ESCAPED HARM. EXITED HIGHWAY INSPECTED VEHICLE. UPON EXITING THE TRUCK FOUND PUDDLE OF BRAKE FLUID ON GROUND UNDER DRIVER'S SEAT. BRAKE LINES LEAKING. SEVER RUST THROUGHOUT THE BRAKE SYSTEM. REPLACEMENT OF ALL BRAKE LINES REQUIRED. THIS WAS VERY CLOSE TO CRASH, ONLY THE RAPID REFLEXES OF THE GUY NEXT TO ME AVERTED AN ACCIDENT. NOTE, REPAIR SHOP TELLS ME THAT (AND HAS SHOWN ME) ALL THE BRAKE LINES MUST BE REPLACED. AS THE LINES ENTER A DISTRIBUTION BOX ( ANTI-LOCK ANTI-SKID UNDER THE DRIVER'S SEAT) AND THE CLAMPING DEVICES ALL HAD SIGNIFICANT RUST TO THE POINT OF FAILURE. *TR
Mileage: 81,000
TL* THE CONTACT OWNS A 2004 GMC SIERRA 3500. THE CONTACT STATED THAT WHEN DEPRESSING THE BRAKES IT WOULD TAKE LONGER THAN NORMAL TO STOP THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO ADVISED HIM THAT HE NEEDED TO REPLACE THE DISK AND ROTORS. THE VEHICLE WAS REPAIRED; HOWEVER, WITHIN APPROXIMATELY 20 MONTHS THE SAME FAILURE RECURRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 15,000.
Mileage: 15,000
TL* THE CONTACT OWNS A 2004 GMC SIERRA 3500 HD. THE CONTACT STATED THAT THERE WAS A LARGE PUDDLE OF UNKNOWN FLUIDS UNDER THE VEHICLE. AFTER INSPECTING THE VEHICLE, THE CONTACT DISCOVERED THAT THE FUEL LINE WAS SEVERELY CORRODED AND CAUSING DIESEL FUEL TO LEAK. THE VEHICLE WAS TAKEN TO A DEALER WHERE THEY ADVISED THE CONTACT THAT THE FUEL LINE NEEDED TO BE REPLACED DUE TO THE CORROSION. THE VEHICLE WAS NOT REPAIRED AND THE MANUFACTURER WAS NOT CONTACTED IN REGARDS TO THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 117,000. UPDATED 02/03/12*LJ THE CONSUMER STATED THE VEHICLE HAS SINCE BEEN REPAIRED. THE BRAKE LINES WERE CORRODED AS WELL. UPDATED 02/08/12
Mileage: 117,000
TL* THE CONTACT OWNS A 2004 GMC SIERRA 3500 HD. THE CONTACT STATED THAT THERE WAS A LARGE PUDDLE OF UNKNOWN FLUIDS UNDER THE VEHICLE. AFTER INSPECTING THE VEHICLE, THE CONTACT DISCOVERED THAT THE FUEL LINE WAS SEVERELY CORRODED AND CAUSING DIESEL FUEL TO LEAK. THE VEHICLE WAS TAKEN TO A DEALER WHERE THEY ADVISED THE CONTACT THAT THE FUEL LINE NEEDED TO BE REPLACED DUE TO THE CORROSION. THE VEHICLE WAS NOT REPAIRED AND THE MANUFACTURER WAS NOT CONTACTED IN REGARDS TO THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 117,000. UPDATED 02/03/12*LJ THE CONSUMER STATED THE VEHICLE HAS SINCE BEEN REPAIRED. THE BRAKE LINES WERE CORRODED AS WELL. UPDATED 02/08/12
Mileage: 117,000
BRAKE FAILURE DUE TO RUSTED OUT BRAKE LINES, ALSO ON-GOING SINCE TRUCK WAS NEW WITH ABS ENGAGING AT SLOW DOWN DUE TO CORRODED SENSORS. *TR
Mileage: 92,000
TL* THE CONTACT OWNS A 2004 GMC SIERRA 3500. WHILE DRIVING APPROXIMATELY 40 MPH, THE VEHICLE BECAME RESISTANT TO ACCELERATION. THE VEHICLE WAS THEN TOWED TO THE DEALER WHERE THE TECHNICIANS STATED THAT ALL EIGHT FUEL INJECTORS WOULD NEED TO BE REPLACED. THE VEHICLE WAS REPAIRED. AFTER THE REPAIRS WERE MADE, THE FAILURE RECURRED. THE CONTACT STATED THE PREVIOUS OWNER OF THE VEHICLE EXPERIENCED THE SAME FAILURE AND HAD THE FUEL INJECTORS REPLACED. THE VEHICLE WAS THEN TRADED FOR ANOTHER VEHICLE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 149,411.
Mileage: 149,411
FUSE BOX UNDER HOOD CAUGHT FIRE WHILE PARKED. *TR
Mileage: 102,000
TL* THE CONTACT OWNS A 2004 GMC PICK UP 3500. THE CONTACT STATED THAT WHEN APPLYING THE BRAKE, THE PEDAL FELL FURTHER INTO THE FLOORBOARD THAN USUAL AND THE BRAKE LIGHTS FAILED TO ILLUMINATE. THE VEHICLE WAS TOWED TO THE DEALER FOR DIAGNOSIS WHERE THE CONTACT WAS INFORMED THAT THE RETAINER CHIP FOR THE HYDRO-BOOST AND BRAKE SWITCH WAS MISSING AT THE BRAKE PEDAL. THE DEALER REPLACED THE CLIP AND THE BRAKE SWITCH WAS REINSTALLED. IN ADDITION, WHILE TEST DRIVING THE VEHICLE THE DEALER ADVISED THAT THE STEERING WHEEL WAS PRODUCING AN ABNORMAL SOUND AND ADVISED THE CONTACT THAT THE LOWER BEARING ASSEMBLY WAS WORN. THE STEERING WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 38,338.
Mileage: 38,338
TL* THE CONTACT OWNS A 2004 GMC PICK UP 3500. THE CONTACT STATED THAT WHEN APPLYING THE BRAKE, THE PEDAL FELL FURTHER INTO THE FLOORBOARD THAN USUAL AND THE BRAKE LIGHTS FAILED TO ILLUMINATE. THE VEHICLE WAS TOWED TO THE DEALER FOR DIAGNOSIS WHERE THE CONTACT WAS INFORMED THAT THE RETAINER CHIP FOR THE HYDRO-BOOST AND BRAKE SWITCH WAS MISSING AT THE BRAKE PEDAL. THE DEALER REPLACED THE CLIP AND THE BRAKE SWITCH WAS REINSTALLED. IN ADDITION, WHILE TEST DRIVING THE VEHICLE THE DEALER ADVISED THAT THE STEERING WHEEL WAS PRODUCING AN ABNORMAL SOUND AND ADVISED THE CONTACT THAT THE LOWER BEARING ASSEMBLY WAS WORN. THE STEERING WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 38,338.
Mileage: 38,338
TL*THE CONTACT OWNS A 2004 GMC SIERRA DORMAX DIESEL (NA). THE CONTACT STATED THAT THE FUEL INJECTORS PRODUCE WHITE SMOKE. OCASSIONALLY, THE VEHICLE BECOMES DIFFICULT TO START. THE CONTACT SERVICED THE INJECTORS EVERY 10,000 MILES, BUT THE FAILURE IS PERSISTENT. THE VEHICLE WAS TAKEN TO THE DEALER AND THEY KEPT REPLACING THE INJECTORS, BUT TO NO AVAIL. THE FAILURE MILEAGE WAS 30,000.
Mileage: 30,000
TL*THE CONTACT OWNS A 2004 GMC SIERRA 3500. THE VEHICLE HAS POWER KING TOWMAX TIRES, SIZE LT235/80R16E. WHILE PULLING THE TRAILER AT 65 MPH, THE SIDEWALL ON THE PASSENGER TIRE BLEW OUT. NO REPAIRS HAVE BEEN MADE. THE CAUSE OF THE FAILURE WAS UNKNOWN. THE FAILURE MILEAGE WAS 600.
Mileage: 600
SPEEDOMETER ERRATICALLY SHOWS INCORRECT SPEED WHILE DRIVING. SOMETIMES DISPLAYING 120MPH OR 0MPH. VERY DANGEROUS AND SHOULD BE A MANDATORY RECALL CHECKED WITH DEALER AND WOULD COST $800.00 TO REPLACE BAD INSTRUMENT CLUSTER. ONLY HAS 73,000 MILES. *TR
Mileage: 73,000
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.
Read our methodology - how this data is sourced, computed, and verified.