Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety.

Print this page


hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
98,975 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2004 Chevrolet Silverado 2500 engine problems

engine problem

Find something helpful? Spread the word.
Get notified about new defects, investigations, recalls & lawsuits for the 2004 Chevrolet Silverado 2500:

Unsubscribe any time. We don't sell/share your email.

2004 Chevrolet Silverado 2500 Owner Comments

problem #11

Jul 032015

Silverado 2500

  • 56,000 miles


Passenger side exhaust manifold bolts rust and break off on all GM full size trucks. I have 2004 Silverado 2500 hd with 61K miles, problem started at 56K miles as a mild tick that went away when engine warmed up and progressed to constant leak when engine was under load, two rear exhaust manifold bolts broke off causing exhaust leak. Seems all truck engines have this problem from 1999 -2007. This sounds like a manufacturing defect that should be addressed by GM.

- Newburgh, NY, USA

problem #10

Oct 012014

Silverado 2500 8-cyl

  • 113,250 miles
Exhaust manifold bolt on driver side at rearmost part of engine has broken off.

- Fitzgerald, GA, USA

problem #9

Oct 072014

Silverado 2500

  • 100,000 miles
After discovering an exhaust leak performed a visual inspection of the engine. I have a 2004 Silverado with the 6.0L. I ave discovered that there are an abundance of these vehicles out there with the same problem. This is causing exhaust fumes to enter the engine compartment and cab of the vehicle.

- Pearl River, LA, USA

problem #8

May 052010

Silverado 2500 4WD 8-cyl

  • 89,000 miles


Exhaust manifold bolts broke on both sides of engine, 6.0 liter engine, resulting in extreme noise, poor gas mileage, service engine light blinking and smell of exhaust entering cab. Why isn't this a recall item since so many people are having the same problem with Chevy and GM trucks and SUV's? the cost of repair by a garage is astronomical and it's impossible to do it ourselves. The truck now has roughly 112,000 miles since we have to use it at times.

- Hoyt Lakes, MN, USA

problem #7

Jun 132014

Silverado 2500 4WD 8-cyl

  • 52,000 miles
In Wyoming, traveling I90 to hyw 16 mountain pass...7 per cent grade....after two miles engine overheated and had to pull over to let engine cool down...had to take another route to bypass mountain. Googled duramax overheating and found this was a very common problem on the 2004 duramax problem prevented adequate air from entering engine...should have been a recall or at least GM should have offered a solution...

- Kingman, IN, USA

problem #6

Jun 012010

Silverado 2500

  • 130,000 miles
The contact owns a 2004 Chevrolet Silverado. The contact stated that while driving at various speeds, the check engine light illuminated and the vehicle suddenly stalled. The contact indicated that after restarting the engine the vehicle operated as normal. The contact also indicated that the passenger side seat belt had malfunctioned and the passenger was unable to move while the seat belt was in the locked position. The vehicle was not diagnosed or repaired. The manufacturer was notified of the defect but no solution was offered. The failure mileage was 130,000.

- Evanston, WY, USA

problem #5

Jun 302014

Silverado 2500 8-cyl

  • 99,470 miles


I have the castech heads on my truck that are known for getting cracks in them and leaking anitifreeze into the engine. The way it sounds there should of been a recall on these heads, this isn't a normal wear and tear deal. Why should the consumer pay for the cost of replacing something that obviously is a manufacturer defect since more than just one person is complaining. It seems like also that GM has helped a few people and then told others that they can't help.

- Kansas City, MO, USA

problem #4

Jun 152013

Silverado 2500

  • 60,000 miles
The bolts are braking off the exhaust manfolds and the manifolds are leaking and the computer is making the truck go into reduced power.

- Medford, MA, USA

problem #3

Feb 012013

Silverado 2500

  • 110,000 miles
The contact owns a 2004 Chevrolet Silverado. The contact stated that the vehicle was blowing cold air and the defroster failed. The vehicle was taken to the dealer who stated the cylinder head had cracked. The vehicle was not repaired. The manufacturer was made aware of the failure however provided no further assistance. The failure mileage was 110,000. The current mileage was 112,000.

- Haverhill , MA, USA

problem #2

Apr 272013

Silverado 2500 8-cyl Diesel

  • 119,000 miles
Engine lost power in heavy traffic at highway speed due premature failure of diesel fuel injector. Come to find out injector have known defect and high failure rate.

- Apache Junction, AZ, USA

problem #1

Aug 072012

Silverado 2500 8-cyl

  • 160,000 miles
I went out to leave for a meeting and started my truck. I heard a ticking noise that I had not heard prior to this morning. I opened the hood to investigate the cause of the ticking and discovered on the left bank one of the exhaust manifold bolts was missing the head. I then went around to the right bank and noticed that the exhaust manifold was broken completely about mid way of the manifold. I have owned this vehicle since it was new off the dealership and have had very little issue with it until this issue popped up. I have done some research and discovered that this is a major problem affecting Chevrolet and GM vehicles with 8 cylinder engines. This vehicle is used as a daily driver and is not used for commercial towing, nor is it used for towing on a regular basis.

- Corsicana, TX, USA

Not what you are looking for?