2004 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated September 2026
2004 · All trims · All engines
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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Chevrolet Blazer has 4 documented known issues, with 2 rated critical. The most serious are 4.3L V6 Lower Intake Manifold Gasket Coolant Leak ($500-$1,100 repair) and In-Tank Fuel Pump Premature Failure and Stalling ($450-$900 repair). Across all issues with published estimates, repair costs range from $80 to $1,100. DIY maintenance guides at au7o.io.
EXTERIOR LIGHTING:BRAKE LIGHTS:SWITCH
GENERAL MOTORS IS RECALLING 5,862 MY 2000-2002 CHEVROLET BLAZER, MY 2000-2001 GMC JIMMY, AND MY 2000 OLDSMOBILE BRAVADA SPORT UTILITY VEHICLES. THE MULTIFUNCTION SWITCH COULD DEVELOP AN OPEN CIRCUIT CONDITION THAT RESULTS IN THE STOP LAMPS AND THE REAR HAZARD LAMPS BECOMING INOPERATIVE. THE CENTER HIGH MOUNTED STOP LAMP AND TURN SIGNAL FUNCTIONS ARE NOT AFFECTED.
EXTERIOR LIGHTING:BRAKE LIGHTS:SWITCH
VEHICLE DESCRIPTION: SPORT UTILITY VEHICLES. THE MULTIFUNCTION SWITCH COULD DEVELOP AN OPEN CIRCUIT CONDITION THAT RESULTS IN THE STOP LAMPS AND THE REAR HAZARD LAMPS BECOMING INOPERATIVE. THE CENTER HIGH MOUNTED STOP LAMP AND TURN SIGNAL FUNCTIONS ARE NOT AFFECTED.
SEAT BELTS
VEHICLE DESCRIPTION: PASSENGER VEHICLES, LIGHT DUTY TRUCKS, SPORT UTILITY VEHICLES, AND MINI VANS EQUIPPED WITH TRW SEAT BELT BUCKLE ASSEMBLIES. THE BUCKLE BASE OF THESE SEAT BELT ASSEMBLIES WERE NOT PROPERLY HEAT TREATED AND THEREFORE DO NOT PASS THE LOAD BEARING REQUIREMENT OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 209, "SEAT BELT ASSEMBLIES."
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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Chevrolet Blazer has 4 documented issues. The most frequently reported are: 4.3L V6 Lower Intake Manifold Gasket Coolant Leak, In-Tank Fuel Pump Premature Failure and Stalling, Electric-Shift Transfer Case Encoder Motor and TCCM Failure (Service 4WD Light). Of these, 2 are rated critical and should be addressed promptly.
The 2004 Chevrolet Blazer has 4 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 2 issues are rated critical: 4.3L V6 Lower Intake Manifold Gasket Coolant Leak and In-Tank Fuel Pump Premature Failure and Stalling. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
Repair costs for known Chevrolet Blazer issues range from $80 to $1,100, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, 4.3L V6 Lower Intake Manifold Gasket Coolant Leak, typically costs $500-$1,100 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
The Vortec 4.3L V6 (like its 5.0L/5.7L siblings) used plastic-carrier lower intake manifold gaskets that erode and crack at the coolant ports from repeated thermal expansion cycles between the aluminum manifold and iron heads. Failures cluster between roughly 80,000 and 150,000 m… Repairs typically run $500-$1,100. Severity: high.
Blazer in-tank fuel pumps fail well before normal service life — NHTSA complaints document failures from roughly 34,000 to 102,000 miles (averaging around 44,000 on the 2000 model year), often preceded by an erratic fuel gauge from the integrated sending unit corroding. GM produc… Repairs typically run $450-$900. Severity: high.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.
EQUIPMENT:OTHER:LABELS
CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 208, "OCCUPANT CRASH PROTECTION."
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Push-button 4WD Blazers use an electric encoder motor on the NP1 electronic-shift transfer case, commanded by the Transfer Case Control Module (TCCM). The encoder motor's internal position sensor and gears wear out, and TCCM faults are equally common, so the transfer case fails t… Repairs typically run $250-$700. Severity: medium.
The heavy doors on two-door S-10 Blazers ride on small hinge pins with soft brass bushings that wear out — accelerated by lack of lubrication — letting the bushing holes in the hinge plates wallow out egg-shaped. The door then drops when opened, no longer aligns with the striker,… Repairs typically run $80-$300. Severity: low.
