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 GMC Sierra 1500 has 8 documented known issues, with 3 rated critical. The most serious are Rusting Brake Lines Leading to Fluid Loss and Sudden Brake Failure ($800-$2,500 repair), 4L60-E / 4L65-E Sun Shell Failure Causing Loss of Reverse and 2nd/4th Gear ($1,800-$3,500 repair) and Fuel Pump Module Failure Causing No-Start or Stalling ($500-$1,200 repair). Across all issues with published estimates, repair costs range from $150 to $3,500. DIY maintenance guides at au7o.io.
EQUIPMENT
General Motors LLC (GM) is recalling certain 2009-2014 Chevrolet Silverado HD and GMC Sierra HD, 2009 GMC Topkick 5000, 6000, 7000 and 8000 Series and Isuzu F Series, and 2009-2018 Chevrolet Express, and GMC Savana vehicles, equipped with certain Plastic-Handle Fire Extinguishers or Push Button 'Pindicator' Fire Extinguishers. These extinguishers may become clogged, preventing the extinguisher from discharging as expected or requiring excessive force to activate the extinguisher. Additionally, in certain models, the nozzle may detach from the valve assembly with enough force that it could cause injury and also render the product inoperable. For a full list of the affected fire extinguisher models visit: https://static.nhtsa.gov/odi/rcl/2017/RMISC-17E062-5427.pdf
AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE
General Motors, LLC (GM) is recalling certain 2014 Cadillac Escalade, Escalade ESV, Chevrolet Silverado 2500, Silverado 3500, Suburban, Tahoe, GMC Sierra 2500, Sierra 3500, Yukon, and Yukon XL vehicles originally sold, or ever registered, in the states of AL, CA, FL, GA, HI, LA, MS, SC, TX, PR, AS, GU, the MP, and VI or "Zone A." Additionally GM is recalling certain 2011-2014 Cadillac Escalade, Escalade ESV, Chevrolet Silverado 2500, Silverado 3500, Suburban, Tahoe, GMC Sierra 2500, Sierra 3500, Yukon, Yukon XL and 2011-2013 Cadillac Escalade EXT, Chevrolet Avalanche, Silverado 1500, and GMC Sierra 1500 vehicles originally sold, or ever registered, in the states of AZ, AR, DE, DC, IL, IN, KS, KY, MD, MO, NE, NV, NJ, NM, NC, OH, OK, PA, TN, VA, and WV or "Zone B." Additionally, GM is recalling certain 2010-2014 Cadillac Escalade, Escalade ESV, Chevrolet Silverado 2500, Silverado 3500, Suburban, Tahoe, GMC Sierra 2500, Sierra 3500, Yukon, and Yukon XL and 2010-2013 Cadillac Escalade EXT, Chevrolet Avalanche, Silverado 1500, and GMC Sierra 1500 vehicles originally sold, or ever registered, in the states of AK, CO, CT, ID, IA, ME, MA, MI, MN, MT, NH, NY, ND, OR, RI, SD, UT, VT, WA, WI, and WY or "Zone C." These vehicles are equipped with non-desiccated passenger frontal inflators containing phase-stabilized ammonium nitrate (PSAN) propellant. These inflators may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, high temperatures, and high temperature cycling.
AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE
General Motors, LLC (GM) is recalling certain 2012 Cadillac Escalade, Escalade ESV, Escalade EXT, Chevrolet Avalanche, Silverado 1500, Silverado 2500/3500, Suburban, Tahoe, GMC Sierra 1500, Sierra 2500/3500, Yukon, and Yukon XL originally sold, or ever registered, in the states of Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands or "Zone A." These vehicles are equipped with non-desiccated passenger frontal inflators containing phase-stabilized ammonium nitrate (PSAN) propellant. These inflators may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, high temperatures, and high temperature cycling.
AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE
General Motors, LLC (GM) is recalling certain 2013 Cadillac Escalade, Escalade ESV, and Escalade EXT, Chevrolet Avalanche, Silverado 1500, Silverado 2500/3500, Suburban, Tahoe, GMC Sierra 1500, Sierra 2500/3500, Yukon, and Yukon XL vehicles originally sold, or ever registered, in the states of Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands or "Zone A." Additionally, GM is recalling certain 2010 Cadillac Escalade, Escalade ESV, and Escalade EXT, Chevrolet Avalanche, Silverado 1500, Silverado 2500/3500, Suburban, Tahoe, GMC Sierra 1500, Sierra 2500/3500, Yukon, and Yukon XL vehicles originally sold, or ever registered in the states of Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia, and West Virginia or "Zone B." Additionally, GM is recalling certain 2009 Cadillac Escalade, Escalade ESV, and Escalade EXT, Chevrolet Avalanche, Silverado 1500, Silverado 2500/3500, Suburban, Tahoe, GMC Sierra 1500, Sierra 2500/3500, Yukon, and Yukon XL vehicles originally sold, or ever registered, in the states of Alaska, Colorado, Connecticut, Idaho, Iowa, Maine, Massachusetts, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, Oregon, Rhode Island, South Dakota, Utah, Vermont, Washington, Wisconsin, and Wyoming or "Zone C."
AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE
General Motors, LLC (GM) is recalling certain 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT, Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe, GMC Sierra 1500, Yukon, Yukon XL, and 2009-2011 Chevrolet Silverado 2500, Silverado 3500, GMC Sierra 2500 and Sierra 3500 vehicles originally sold, or ever registered, in the states of Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands or "Zone A." Additionally, GM is recalling certain 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT, Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe, GMC Sierra 1500, Yukon, Yukon XL vehicles originally sold, or ever registered, in the states of Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia, and West Virginia or "Zone B." These vehicles are equipped with non-desiccated passenger frontal inflators containing phase-stabilized ammonium nitrate (PSAN) propellant. These inflators may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, high temperatures, and high temperature cycling.
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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 GMC Sierra 1500 has 8 documented issues. The most frequently reported are: Rusting Brake Lines Leading to Fluid Loss and Sudden Brake Failure, 4L60-E / 4L65-E Sun Shell Failure Causing Loss of Reverse and 2nd/4th Gear, Fuel Pump Module Failure Causing No-Start or Stalling. Of these, 3 are rated critical and should be addressed promptly.
The 2004 GMC Sierra 1500 has 8 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 3 issues are rated critical: Rusting Brake Lines Leading to Fluid Loss and Sudden Brake Failure and 4L60-E / 4L65-E Sun Shell Failure Causing Loss of Reverse and 2nd/4th Gear and Fuel Pump Module Failure Causing No-Start or 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 GMC Sierra 1500 issues range from $150 to $3,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Rusting Brake Lines Leading to Fluid Loss and Sudden Brake Failure, typically costs $800-$2,500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
Corrosion of steel brake lines is a major safety issue on older Sierra 1500 trucks, especially in salt-belt states. Owners report the brake pedal suddenly dropping to the floor when a rusted line bursts during normal braking, often near the ABS module or along the frame rails. Th… Repairs typically run $800-$2,500. Severity: high.
On GMT800 Sierra 1500 trucks equipped with the 4L60-E family automatic, a well-known internal failure is cracking or stripping of the reaction sun shell. Owners commonly report sudden loss of reverse, no 2nd gear, no 4th gear, or a truck that starts in 3rd gear after a bang or fl… Repairs typically run $1,800-$3,500. Severity: high.
A common GMT800 Sierra problem is failure of the in-tank fuel pump module, often from worn pump motors or failed level-sender/module electronics. Owners report long crank, hard starting, loss of power under load, or sudden stall/no-start conditions, especially as mileage climbs. Repairs typically run $500-$1,200. Severity: high.
The 4.8L, 5.3L, and 6.0L Vortec engines used in early GMT800 Sierra trucks place the knock sensors in wells beneath the intake manifold, where water can collect and corrode the sensors or harness. Owners frequently report recurring check-engine lights, timing retard, and reduced… Repairs typically run $400-$900. Severity: medium.
Front wheel hub bearing assemblies on Sierra 1500 trucks commonly wear out, especially on 4WD models and trucks used with larger tires or in rough conditions. Owners report humming or growling that changes with speed, looseness in the front wheel, and in some cases ABS warnings o… Repairs typically run $300-$900. Severity: medium.
A very common GMT800 complaint is sulfur contamination and wear of the fuel level sensor contacts inside the tank module, causing the gauge to read empty, full, or fluctuate unpredictably. Owners often see a low-fuel warning with plenty of fuel in the tank or watch the gauge drop… Repairs typically run $450-$1,100. Severity: medium.
2003-2007 Classic-era Sierra trucks are well known for instrument cluster gauge failures caused by defective stepper motors and, in some cases, backlighting issues. Speedometer, tachometer, oil pressure, fuel, voltage, and coolant gauges can stick, read wildly high or low, or sto… Repairs typically run $250-$700. Severity: medium.
Sierra owners across both GMT800 and GMT900 generations frequently report small electric HVAC actuators stripping internal gears or losing calibration. The result is a repetitive clicking or tapping noise from the dash, air stuck on defrost or floor, or one side blowing hot while… Repairs typically run $150-$700. Severity: medium.
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.
