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hardly worth mentioning
Crashes / Fires:
0 / 1
Injuries / Deaths:
0 / 0
Average Mileage:
65,600 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 Suburban fuel system problems

fuel system problem

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2004 Chevrolet Suburban Owner Comments

problem #8

Dec 202010

Suburban 8-cyl

  • 130,000 miles


Instrument cluster failed after extreme cold temperatures, fuel gauge, temperature gauge, oil pressure gauge and battery charging system gauge. GM knows about the faulty gauges and as of this date has not made a recall of the instrument panel. Considering all legal remedies afforded by law as this is a problem that can be rectified by GM by replacing the aforementioned faulty factory equipment.

- Corpus Christi, TX, USA

problem #7

May 072011

Suburban 4WD 8-cyl

  • 93,409 miles
I have a 2004 Chevy Suburban with 93409 mile, has been well taken care of. A few months ago I notice it was having a hard time starting. Last wk we ran out of gas at 1.4 tank and this weekend while the family was on a trip pulling a trailer we ran out of gas at 1/2 tank, if you go by the gas gage. We could have been badly hurt if we were on a hill, or something when we all of a sudden have no powersteering, brakes, etc.

- Roseville, MI, USA

problem #6

Nov 012010


  • 65,000 miles
The contact owns a 2004 Chevrolet Suburban. The contact stated that the fuel gauge was reading inaccurately and he was unable to determine how much fuel was in the vehicle. The contact did not inform the dealer or manufacturer of the failure nor was the vehicle repaired. The current mileage was 95,000 and the failure mileage was 65,000. The VIN was unavailable.

- Auburndale, FL, USA

problem #5

Feb 122009


  • miles


Fuel gauge is not accurately reporting fuel level. When fuel level is too low, vehicle shuts down and will not restart. Low level warning light does not come on. Vehicle has to be jump started in order to reset security mechanism. Can cause traffic issues and/or collision from abruptness of issue and happens without warning wherever you are. I can just imagine what a problem it would be if it happened in an intersection or running down the highway. Since the vehicle shuts down, this would mean power steering and power brakes would be non-functional increasing the potential risk for an accident or collision.

- Albuquerque, NM, USA

problem #4

Mar 092009


  • 60,230 miles
2004 Suburban with less than 65000 miles, cuts out driving at various speeds, sitting at traffic light, uphill or down hill. Vehicle gives no warning, no lights light up, just all of a sudden no power. Can start back up sometimes immediately, sometimes after several minutes. After researching online seems to be a common problem issue with the vehicle, called dealer and they said there is no recall even though it is obviously a safety issue.

- Leeds, AL, USA

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problem #3

Dec 012008


  • 93,162 miles
2004 Suburban had leak in gas tank. Evap lines on top of fuel tank leaking gas over tank and on ground. Had lines replaced on Dec.16, 2008 and leak has reappeared Jan. 11, 2009.

- Piedmont, SC, USA

problem #2

May 172008


  • miles
In researching online I've noticed this on many different Chevy 2004 models. The tachometer, fuel gage, and speedometer are what I noticed problems with and what others have seen problems with though the speedometer is the most prevalently noticed item. The gauge motors are not stepping back down when rpms, speed, or fuel levels drop thus leading drivers to respond in potentially dangerous ways. In my own case I almost caused a pile up when I thought I had lost my senses and applied my brakes a little harder than I should have, almost lost control of the vehicle, and certainly agitated the drivers behind me when they almost hit my vehicle. I don't typically get this problem as I typically drive less than 10 miles a day. When I do have to drive more than 60 miles I tend to have this problem. The problem has also been reported to be more prevalent in cold conditions which fits with the explanation I have had that it is the housing of the gear motors breaking down and jamming the gauge gears in the instrument panel. A problem with the plastic used in the housing of the gear magnets; "the problem lies with the plastic material that holds the permanent magnet for the rotor of the stepper motor." Now that I am aware of the problem and have asked around about fixes I have to stop the vehicle completely and turn it off. From there I have to turn the key enough to bring the instrument panel momentarily on and then back off. It steps the tachometer, speedometer, and fuel gauge back down, (bit by bit with each turn of the key) whichever is having the problem. This solution has been reported to stop working as the problem persists. The instrument panel needs to be replaced at a cost estimate of over $450 from a private shop and at over $800 from the Chevy dealership. A gps for speed and a log book w/ calculator can get two of the three solved for me at a price of less than $200; it's just not safe to be writing log book entries while I'm driving.

- Huntsville, TX, USA

problem #1

Mar 082007

Suburban 8-cyl

  • 83,000 miles
Parked in a wet, muddy field, not running, my 2004 Chevrolet Suburban, caught fire and exploded.

- Flower Mound, TX, USA

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