2004 CHEVROLET SILVERADO 2500 Engine And Engine Cooling Problems

TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO. THE CONTACT STATED THAT THE BOLTS ON THE EXHAUST MANIFOLD WERE FRACTURING. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE TECHNICIAN DIAGNOSED THAT THE MANIFOLD NEEDED TO BE REPLACED. NO REPAIRS WERE MADE TO THE VEHICLE. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 93,500. UPDATED 12/19/14*CN THE CONSUMER STATED THE MANUFACTURER SHOULD BE RESPONSIBLE FOR THE FAILURE. THERE WAS A CHANCE OF FIRE OR COMPLETE FAILURE CAUSING INJURIES IF THE MANIFOLD BREAKS AWAY FROM THE VEHICLE. UPDATED 05/26/2015 *JS

Mileage: 93,500

EXHAUST MANIFOLD BOLTS BROKE OFF FOR NO REASON, LETTING EXHAUST FUMES ESCAPE UNDER THE HOOD AND IN THE CAB OF THE TRUCK. THIS SEEMS TO BE A VERY COMMON PROBLEM ON SEVERAL GM TRUCKS. *JS

MY TRUCK IS A 2004 CHEVY SILVERADO 2500 WITH 94000 MILES AND THE REAR DRIVER SIDE EXHAUST MANIFOLD BOLT HEAD IS BUSTED OFF. THIS IS NOT THE ONLY CHEVY/GMC 4.8,5.3 OR 6.0 ENGINE THAT HAS THIS PROBLEM. MILLIONS OF OTHERS HAVE THIS SAME PROBLEM AND FROM THIS FAILURE IT CAN LEAD TO FUTURE EMISSION PROBLEMS, CATALYTIC CONVERTER PROBLEMS, EXHAUST LEAK IN THE ENGINE COMPARTMENT LEADING TO EXHAUST FUMES BEING LEAKED INTO THE CAB OF THE VEHICLE WHICH WOULD BE CARBON MONOXIDE POISONING. THIS IS A MAJOR ISSUE THAT GM SHOULD TAKE CARE OF AS A RECALL !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! *TR

Mileage: 80,000

FOUR EXHAUST MANIFOLD BOLTS HAVE BROKEN OFF SINCE I'VE OWNED THIS TRUCK AND THE MANIFOLD HAS CRACKED. IT IS A DESIGN FLAW THAT OCCURS IN MANY OF THE SIMILAR V8 EQUIPPED MODELS AND HAS BEEN WELL DOCUMENTED ON THE INTERNET. THIS SHOULD BE RECALLED BY GM. THIS PROBLEM ALSO LEADS TO FAULTY EMISSION READINGS BY THE VEHICLE AND THE CHECK ENGINE LIGHT WILL GO ON AND REMAIN ON UNTIL THIS EXPENSIVE PROBLEM IS FIXED. *TR

Mileage: 100,950

TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500 HD. THE CONTACT STATED THAT WHILE TOWING A TRAILER AT APPROXIMATELY 55 MPH, A CLICKING NOISE WAS HEARD FROM THE ENGINE AND THE ENGINE EXPLODED. THE CONTACT ALSO OBSERVED SMOKE RISING FROM THE ENGINE DURING THE FAILURE. THE VEHICLE WAS TOWED TO AN INDEPENDENT REPAIR SHOP WHERE THE CONTACT WAS INFORMED THAT THE ENGINE EXPLODED AND ALL OF ITS COMPONENTS WERE MELTED. THE VEHICLE WAS THEN TOWED TO AN AUTHORIZED DEALER WHERE THE FAILURE WAS CONFIRMED AND THE CONTACT WAS ADVISED THAT THE ENGINE WAS DESTROYED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE, BUT OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS 55,000.

Mileage: 55,000

I HAVE A 2004 SILVERADO K2500 WITH A DURAMAX DIESEL (LLY). I BOUGHT THIS TRUCK NEW IN SEPTEMBER 2004. I PULL A FIFTH WHEEL CAMPER. MY TRUCK HAS OVERHEATED MORE THAN TWO DOZEN TIMES, AND ON SOME OCCASIONS LOST POWER, WHILE PULLING THE CAMPER UP LONG GRADES. I REPORTED THIS PROBLEM TWICE TO CHEVROLET DEALERS. I HAVE THE SERVICE ORDERS THAT CLEARLY DESCRIBE MY OVERHEATING PROBLEM. BOTH OF THESE SERVICE CALLS WERE WHILE THE TRUCK WAS UNDER WARRANTY, BUT THE DEALERS COULD NOT FIX THE PROBLEM. LATER WHEN THE TRUCK WAS OUT OF WARRANTY, I FOUND OUT THAT GENERAL MOTORS RECOGNIZED THE OVERHEATING PROBLEM AND ISSUED A SERVICE BULLETIN #06-06-04-036D THAT DESCRIBES MY HEATING PROBLEM EXACTLY. THIS SERVICE BULLETIN WAS ISSUED PRIOR TO EITHER OF MY COMPLAINTS ABOUT OVERHEATING. THE COST OF IMPLEMENTING SERVICE BULLETIN #06-06-04-036D IS APPROXIMATELY $1,300 DOLLARS, SO GENERAL MOTORS RECOGNIZES THAT THIS SERIES TRUCK HAS A SIGNIFICANT OVERHEATING PROBLEM, BUT APPARENTLY THEY ARE HIDING THIS FIX FROM THE OWNERS UNTIL THE VEHICLE IS OUT OF WARRANTY. I CAN GIVE MANY INSTANCES WHERE THIS OVERHEATING PROBLEM HAS CAUSED A SAFETY PROBLEM. ONE TIME I WAS PULLING THE CAMPER EAST ON INTERSTATE 40 ABOUT A 150 MILES WEST OF ALBUQUERQUE, NM WHEN THE TRUCK OVERHEATED AND LOST POWER. THERE WAS NO GOOD PLACE TO PULL OVER AND I WAS TERRIFIED AS THE HEAVY TRAFFIC HAD TO CHANGE LANES AND PASS ME. ANOTHER TIME I WAS PULLING UP TO THE NORTH RIM OF THE GRAND CANYON ON A TWO LANE ROAD WHEN THE TRUCK OVERHEATED, LOST POWER AND I HAD A LONG LINE OF TRAFFIC BEHIND ME. IT WAS DANGEROUS AS THE TRAFFIC PASSED ME WITHOUT GOOD CLEARANCE. I COULD GO ON AND ON OF SIMILAR SITUATIONS THAT CAUSED DANGEROUS CONDITIONS. THERE IS ALSO A WEBSITE AT WWW.DIESELPLACE.COM THAT HAS AN ENTIRE SECTION DEVOTED TO THE LLY DIESEL. THERE ARE OVER A THOUSAND POSTS CONCERNING THIS OVERHEATING PROBLEM. *TR

Mileage: 32,533

AIR COND. COMPRESSOR FAILED, SEIZED!. *KB

Mileage: 59,000

2004 CHEVROLET SILVERADO 2500HD. CONSUMER STATES GAUGES STOPPED WORKING AND THE BOLTS ON THE MANIFOLD WERE DEFECTIVE. *TGW

Mileage: 77,000

TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500 HD DIESEL. THE CONTACT STATED WHILE DRIVING, THE CHECK ENGINE LIGHT ILLUMINATED AND THE VEHICLE STALLED. THE CONTACT MENTIONED THE FAILURE HAPPENED SEVERAL TIMES. THE VEHICLE WAS TAKEN TO THE DEALER WHO WAS UNABLE TO DIAGNOSE THE FAILURE. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE BUT STATED THEY WOULD CONTACT HIM AT A LATER DATE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS UNKNOWN AND THE CURRENT MILEAGE WAS 124,869.

Mileage: 124,864

I OWN A 2004 CHEVROLET SILVERADO 2500. IT HAS A BROKEN EXHAUST MANIFOLD BOLT. AFTER RESEARCHING THIS PROBLEM ON THE INTERNET, I FOUND THERE ARE APPROXIMATELY 12,000,000 GM VEHICLES WITH THIS PROBLEM. WHY HASN'T THE NHTSA ISSUED A RECALL ON THESE VEHICLES? IT SEEMS TO ME THAT THE EPA WOULD HAVE DONE SOMETHING ABOUT AS THE BROKEN BOLT IS ALLOWING EXHAUST INTO THE AIR WITHOUT GOING THROUGH THE CONVERTER. I DON'T KNOW AT WHAT MILEAGE THE BOLT BROKE OR AT WHAT SPEED I WAS GOING WHEN IT HAPPENED. *TR

Mileage: 85,000

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.

Mileage: 50,000

THE EXHAUST MANIFOLD BOLTS ARE BROKEN ON MY 2004 CHEVROLET 2500 HD TRUCK. THEY ARE ALSO BROKEN ON MY SONS 2004 GMC 2500 HD AND MY BROTHERS 2005 GMC 2500HD. SOMETHING IS WRONG WITH THAT AND SOMETHING SHOULD BE DONE BEFORE THEY CATCH FIRE. *TR

Mileage: 90,000

RECENTLY I DEVELOPED AN EXHAUST LEAK NEAR THE FRONT OF THE EXHAUST SYSTEM NEAR THE ENGINE. UPON INSPECTION I FOUND THE BACK MANIFOLD BOLT HAD BEEN BROKEN OFF ON THE DRIVERS SIDE (I MAY ALSO HAVE A BROKEN BOLT ON THE PASSENGER SIDE AS WELL). I TOOK THE VEHICLE TO MY LOCALLY RESPECTED MECHANIC WITH THE INTENTION OF HAVING THE BROKEN BOLT REMOVED AND A NEW ONE INSTALLED. I WAS NOTIFIED THAT THIS WAS A COMMON PROBLEM WITH THESE GM VEHICLES (2004 SILVERADO 2500HD). I WAS FURTHER INFORMED THAT THERE WAS NO WAY THE REPAIR WOULD BE SIMPLE DUE TO THE FACT THERE WAS NO PRACTICAL MANNER IN WHICH TO EXTRACT/DRILL OUT THE BROKEN BOLT FOR REPLACEMENT. I WAS TOLD THE HEAD WOULD NEED TO BE REMOVED IN ORDER TO EFFECT THE REQUIRED REPAIR WHICH WOULD COST SOMEWHERE BETWEEN $700-$1000. THIS REPAIR IS NOT COST EFFECTIVE TO ME FOR WHAT IS PROBABLY A $3.00 BOLT. RESEARCHING THIS ISSUE ON THE INTERNET I FOUND OUT IT IS IN FACT A PROBLEM WITH THESE VEHICLES DATING BACK TO 1999. WHY HAS GM NOT BEEN REQUIRED TO REPAIR THIS ITEM AT NO COST TO THE OWNER IF IT IS THIS WIDESPREAD. *TR

Mileage: 73,800

BROCKEN EXHAUST MANIFOLD BOLTS. *TR

Mileage: 74,000

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

Mileage: 96,764

TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500. THE CONTACT STATES HE WAS DRIVING AT ABOUT 55MPH ON THE HIGHWAY WHEN HE NOTICED THERE WAS SMOKE COMING FROM UNDER THE HOOD AND THREW THE HEATER VENTS INTO HIS VEHICLE. THE CONTACT STATES HE PULLED HIS VEHICLE OVER INTO A PARKING LOT AND BY THE TIME HE STEPPED OUT OF HIS VEHICLE THERE WAS FLAMES COMING FROM UNDER THE HOOD. THE CONTACT ALSO STATES THE HOOD WOULD NOT OPEN. THE FIRE DEPARTMENT WAS CONTACTED AND WHEN THEY ARRIVED THERE IT TOOK THEM A HOUR TO PUT THE FIRE OUT. THE FIRE REPORT IS AVAILABLE.THE CONTACT STATES HE WAS NOT INJURED. THE VEHICLE WAS DESTROYED. THE FAILURE MILEAGE WAS 43,000. AR

Mileage: 43,000

BOLTS SHEARED ON THE EXHAUST MANIFOLD. *TR

Mileage: 47,000

THIS IS HOW IT STARTED.. I HAVE A 2004 CHEVY SILVERADO 2500 HD. AS I DROVE DOWN THE ROAD THE DOORS WOULD LOCK AND UNLOCK ON THEIR OWN, AND THE TRUCK WOULD LOSE RPM'S AND WOULD ACT AS IF THE TRUCK SHUT OFF AND RESTARTED ITSELF. ALSO THE CHECK ENGINE LIGHT WOULD BLINK WITH THE LOCKING AND UNLOCKING OF THE DOORS. DID THIS OFF AND ON A FEW TIMES AS WE BABIED IT HOME. GOT IT HOME IN THE DRIVEWAY AND IT THREW 2 CODES CAMSHAFT POSITION SENSOR HIGH VOLTS AND LOW VOLTS. SO WE REPLACED THE CAMSHAFT POSITION SENSOR. TRUCK DROVE FINE FOR 4 DAYS. HOWEVER ON THE 5TH DAY WE ATTEMPTED TO DRIVE THE TRUCK AND AS WE WERE DRIVING DOWN THE ROAD THIS TIME THE ENGINE LIGHT CAME ON AND STAYED ON AND DOORS STARTED LOCKING AND UNLOCKING AGAIN ON THEIR OWN AS WELL AS THE DIC READ SERVICE BRAKE SYSTEM AND THE TRUCK COMPLETELY DIED IN THE MIDDLE OF TRAFFIC, WE WERE ABLE TO PULL OVER INTO A PARKING LOT AND TRUCK RESTARTED LONG ENOUGH TO GET HOME. AT THIS POINT THE GM DEALER WASN'T SURE OF THIS PROBLEM AND WHAT CAUSES IT BUT STATED TO UNPLUG THE BATTERY AND RESET THE COMPUTER(AFTER SPEAKING TO 4 DIFFERENT GM DEALERS MIND YOU). WOW LOW AND BEHOLD FIXED THE PROBLEM FOR ABOUT 45 MINUTES, AS WE AGAIN TRIED TO SEE HOW FAR WE COULD MAKE IT BEFORE IT STARTED ACTING UP AGAIN. ONLY THIS TIME DOORS WOULD LOCK AND UNLOCK AND ALL KINDS OF WEIRD THINGS WERE GOING ON, FOR EXAMPLE DOORS LOCKING AND UNLOCKING, TRUCK STALLING AND RESTARTING, IDOL WAS RUFF AND NOISY, SERVICE ENGINE LIGHT CAME ON AND STAYED ON, AND THE DIC READ THIS TIME REDUCED ENGINE POWER!! AND AT THIS POINT WE WERE ONLY ABLE TO GO 15 MILES AN HOUR AND THANKFULLY WE WERE ON A ROAD WITH NO TRAFFIC AND WERE ABOUT 2 MILES FROM OUR HOME. ALSO IN THE MIST OF ALL OF THIS THE TRUCK WAS CHIMING AND THE TRUCK THOUGHT IT DIDN'T HAVE ANY BRAKES AT THIS POINT THANKFULLY WE WERE ABLE TO GET THE TRUCK TO COME TO A COMPLETE STOP. WE HAVE HAD THIS TRUCK FOR LESS THAN 1 YR AND IT ONLY HAS 82,000 ON IT AND NOONE SEEMS TO BE ABLE TO TELL US WHAT IS WRONG WITH IT. *TR

Mileage: 81,098

THREE EXHAUST MANIFOLD BOLTS HEAD SNAPPED OFF, RESULTING IN DANGEROUS EXHAUST BEING EXPELLED UNDER THE HOOD. *TR

Mileage: 44,000

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

Mileage: 95,000

TRUCK OVERHEATED FORCING ME TO RAPIDLY EXIT ROADWAY. PROBLEM IS CONTINUAL, AND NOT RECOGNIZED BY MANUFACTURER AS "PROBLEM" FOR MY MODEL OF TRUCK. *NM

Mileage: 12,363

DT*: THE CONTACT STATED THE VEHICLE'S TIRE HUBS ARE SEALED UNITS AND COULD NOT BE REPACKED WITH GREASE. THE HUB ASSEMBLY WAS LOOSE WHICH CAUSED THE BEARINGS TO BECOME DEFECTIVE RESULTING IN WOBBLING TIRES. THE FRONT HUBS HAD TO BE REPLACED TWICE HOWEVER THE SERVICE DEALER COULD NOT DETERMINE WHY THE BEARINGS WERE BECOMING DEFECTIVE. ALSO, THERE WAS OIL LEAKING OUT OF THE EGR VAVLE. THE EGR VALVE WAS REPLACED WHICH CORRECTED THE PROBLEM. THEN VEHICLE WAS SURGING AND WOULD NOT ACCELERATE. WHEN THE VEHICLE WAS TAKEN TO THE DEALER THE VEHICLE'S EGR VALVE WAS REPLACED AGAIN WHICH ALSO CORRECTED THE PROBLEM. UPDATED 11/06/06.*JB

Mileage: 70,726

AT 35000 MILES THE CHECK ENGINE LIGHT CAME ON AND THE DEALER REPLACED PARTS WITH THE GAS TANK/FUEL LINE DUE TO IT BEING 'PLUGGED'. 10,000 MILES LATER IT HAPPENS AGAIN BUT NO WARRANTY AND AFTER VERY DISSATISFYING SERVICE AT DEALER WE OPTED TO A NEW MECHANIC. HE RESET THE CHECK ENGINE LIGHT BUT 1 WEEK LATER IT WAS ON AGAIN. THEN HE REPLACED THE EMISSIONS LINE AND 3 DAYS LATER THE CHECK ENGINE LIGHT IS ON AGAIN. ONE DEALER STATED THAT EXCESSIVE DRIVING ON GRAVEL ROADS LEADS TO THIS PROBLEM THAT THE FUEL SYSTEM IS NOT VENTED PROPERLY. (??) WE ARE RANCHERS AND THE MAJORITY OF OUR TRAVEL TAKES US ON GRAVEL ROADS. HOPEFULLY SOMEONE FIGURES THIS ONE OUT SO IT CAN BE FIXED....

Mileage: 34,985