2004 Chevrolet W4500 recalls and problems

The 2004 Chevrolet W4500 has 1 safety recall and 1 owner complaint filed with NHTSA. Recall repairs are free at any Chevrolet dealer.

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

Recalls may cover only some 2004 Chevrolet W4500 vehicles. Check your VIN at NHTSA ↗ to see open recalls for your exact car.

2004 Chevrolet W4500 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 W4500 problems reported by owners

Problem areaReports
Fuel System, Other1

Most reported parts

  • Fuel System, Other › Fuel Injection System — 1

Typical mileage at the time of the problem: 73,029 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 W4500 complaints

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

Fuel System, Other · at 73,029 miles · reported Oct 11, 2007
On several occasions with the truck there have been significant amounts of smoke bellowing from the exhaust. In some cases, other autos believe the vehicle was on fire. Injectors have been found to be faulty on three occasions requiring replacement at significant costs. Smoke from the exhaust is due to the faulty injectors not allowing fuel into the engine so as a result the engine is burning only oil and no diesel fuel. Engine is exposed to excessive heat and could start on fire.

Other Chevrolet W4500 years

Compare all Chevrolet W4500 years · All Chevrolet models

Frequently asked questions

Does the 2004 Chevrolet W4500 have any recalls?

Yes — NHTSA lists 1 recall for the 2004 Chevrolet W4500: 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 W4500?

Owners report fuel system, other problems most often (1 reports). The typical mileage when problems were reported is about 73,029 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.