2004 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated May 2026
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 GMC Sonoma has 3 documented known issues. No issues are rated critical, indicating generally reliable ownership. Across all issues, repair costs range from $30 to $900. DIY maintenance guides at au7o.io.
On the 1991-2004 GMC Sonoma, same fuel pump failure issues as the S-10. The in-tank pump fails from heat and debris.
Confirm low fuel pressure before replacing parts by checking pressure at the Schrader valve on the fuel rail; CPI/Vortec-equipped 4.3L trucks are especially sensitive and typically need about 60-66 psi to start and run correctly, while weak pressure, intermittent drop-out, or excessive current draw points to a failing in-tank pump. Inspect the fuel pump relay, fuse, ground at the frame, and the pump electrical connector for heat damage, then replace the complete in-tank fuel pump module/strainer and install a new fuel filter at the same time; on many Sonomas the tank must be lowered, though removing the bed can also improve access on some configurations. Use a quality Delco or Delphi module rather than a pump-only repair, and clean out any tank debris to prevent repeat failure. Typical repair cost is about $450-$900 parts and labor depending on engine, cab/bed configuration, and whether the sending unit harness also needs replacement.
Parts and tips from 0+ owners who fixed this issue
On the 1996-2004 GMC Sonoma 4.3L Vortec V6, same intake gasket issue as the S-10 platform. The 4.3L Vortec V6 intake gaskets fail from heat cycling.
Pressure-test the cooling system and inspect the intake manifold-to-head sealing area for external coolant seepage; on the 4.3L Vortec, leaks commonly occur at the lower intake manifold gaskets and can also show up as unexplained coolant loss or overheating. Repair requires removing the upper plenum and lower intake manifold, cleaning the sealing surfaces, and installing the updated metal/rubber intake manifold gasket set with new bolts if specified, then refilling and properly bleeding the cooling system; many technicians also change the thermostat and coolant during the job. If coolant contamination is found in the oil, change the oil and filter immediately after repair. Typical repair cost is about $700-$1,300 depending on labor rates and whether related items like hoses, thermostat, or distributor components are replaced.
Parts and tips from 0+ owners who fixed this issue
On the 1994-2004 GMC Sonoma, the plastic exterior door handles break at the pivot point, making it impossible to open the door from outside. The brittle plastic cracks in cold weather and from normal UV degradation over time.
Replace exterior door handle (Dorman 77072 driver, 77073 passenger). The replacement is straightforward with removal of the inner door panel. Consider replacing both sides preventively as they fail at similar rates.
Parts and tips from 0+ owners who fixed this issue
FUEL SYSTEM, OTHER:STORAGE:TANK ASSEMBLY:PRESSURE RELIEF DEVICES
CERTAIN DELPHI FUEL PRESSURE REGULATORS, P/NOS. FP10020-11B1, FP10026-11B1, AND FP10027-11B1, SOLD AFTER JANUARY 9, 2007, AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES LISTED ABOVE. THE UNIVERSAL PRESSURE REGULATORS (UPR) WERE PRODUCED WITHOUT AN O'RING AND RETAINER.
EQUIPMENT:OTHER:LABELS
VEHICLE DESCRIPTION: LIGHT DUTY PICKUP TRUCKS AND SPORT UTILITY VEHICLES. SOME OF THESE VEHICLES WERE BUILT WITH INCORRECT PAYLOAD INFORMATION ON THE VEHICLE CERTIFICATION LABEL. THE PAYLOAD SHOWN ON THE LABEL IS GREATER THAN THE MAXIMUM VALIDATED PAYLOAD. IF THE VEHICLE WERE LOADED TO THE INCORRECTLY LABELED PAYLOAD, IT MAY NOT RIDE AND HANDLE IN THE MANNER THAT THE DRIVER EXPECTS.
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."
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."
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP
VEHICLE DESCRIPTION: S -TRUCKS EQUIPPED WITH 2 WHEEL DRIVE. THESE VEHICLES MAY HAVE HAD THE RIGHT-HAND ANTILOCK BRAKE SYSTEM (ABS) MODULE FEED PIPE AND/OR BRAKE CROSSOVER PIPE TUBE NUTS TIGHTENED WITHOUT SEATING THE PIPE-FLARED-ENDS ENOUGH TO WITHSTAND NORMAL ASSEMBLY AND VEHICLE INPUTS WITHOUT PARTIALLY UNSEATING. THIS DOES NOT COMPLY WITH REQUIREMENTS OF FMVSS NO. 105, "HYDRAULIC SERVICE BRAKE NORMAL, EMERGENCY, AND PARK BRAKING PERFORMANCE."
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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004-2004 GMC Sonoma has 3 documented issues. The most frequently reported are: In-Tank Fuel Pump Failure, 4.3L V6 Intake Manifold Gasket Leak, Exterior Door Handle Breakage. None are rated critical, but regular maintenance is recommended.
The 2004-2004 GMC Sonoma has 3 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. No issues are rated critical, suggesting generally good reliability. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
Repair costs for known GMC Sonoma issues range from $30 to $900, depending on the specific problem and whether you choose DIY or professional repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
Same fuel pump failure issues as the S-10. The in-tank pump fails from heat and debris. Repairs typically run $400-$800. Severity: medium.
Same intake gasket issue as the S-10 platform. The 4.3L Vortec V6 intake gaskets fail from heat cycling. Repairs typically run $400-$900. Severity: medium.
The plastic exterior door handles break at the pivot point, making it impossible to open the door from outside. The brittle plastic cracks in cold weather and from normal UV degradation over time. Repairs typically run $30-$150. Severity: low.
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.
