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2004 Chevrolet W3500 recalls and problems

The 2004 Chevrolet W3500 has 1 safety recall and 4 owner complaints filed with NHTSA. Recall repairs are free at any Chevrolet dealer.

Recalls
1
Complaints
4
Crashes / fires
0 / 0
Injuries / deaths
0 / 0

Recalls may cover only some 2004 Chevrolet W3500 vehicles. Check your VIN at NHTSA ↗ to see open recalls for your exact car.

2004 Chevrolet W3500 recalls

Recall 05V-168: Fuel System, Diesel

Reported Apr 20, 2005 · 253 vehicles affected · ISUZU MANUFACTURING SERVICES OF AMERICA

Problem: 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.

Fix: 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.

2004 Chevrolet W3500 problems reported by owners

Problem areaReports
Engine and Engine Cooling3
Fuel System, Gasoline2
Electrical System1
Suspension1
Service Brakes, Hydraulic1
Structure1

Most reported parts

  • Fuel System, Gasoline › Delivery › Fuel Pump — 1
  • Fuel System, Gasoline › Delivery › Hoses, Lines/Piping, and Fittings — 1
  • Suspension › Rear › Shock Absorber — 1
  • Service Brakes, Hydraulic › Foundation Components — 1
  • Engine and Engine Cooling › Exhaust System — 1
  • Engine and Engine Cooling › Exhaust System › Manifold/Header/Muffler/Tail Pipe — 1

Typical mileage at the time of the problem: 152,000 miles (median of owner reports).

Problems that are not covered by a recall are paid repairs; labor rates follow local mechanic pay — see what auto mechanics earn in each state.

Recent 2004 Chevrolet W3500 complaints

Owner reports filed with NHTSA, as written (personal details removed). Complaints are not verified by NHTSA.

Engine and Engine Cooling · at 63,000 miles · reported Aug 13, 2014
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.
Engine and Engine Cooling · at 152,000 miles · reported Apr 13, 2011
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 the consumer stated the vehicle has a cracked exhaust manifold. Updated 05/26/11
Suspension · at 215,900 miles · reported May 24, 2007
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.
Fuel System, Gasoline · reported Sep 29, 2004
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.

Other Chevrolet W3500 years

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Compare all Chevrolet W3500 years · All Chevrolet models

Frequently asked questions

Does the 2004 Chevrolet W3500 have any recalls?

Yes — NHTSA lists 1 recall for the 2004 Chevrolet W3500: 05V-168 (fuel system, diesel). Not every vehicle is affected, so check your VIN at nhtsa.gov/recalls.

What is the most common problem with the 2004 Chevrolet W3500?

Owners report engine and engine cooling problems most often (3 reports), followed by fuel system, gasoline (2). The typical mileage when problems were reported is about 152,000 miles.

Are Chevrolet recall repairs free?

Yes. Safety recall repairs are free at authorized Chevrolet dealers, whether you are the first owner or bought the car used.