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. Notes: It would be ill-advised to blaze any trails with the 2004 Trailblazer. Its faulty fuel gauge could leave you stranded.


fairly significant
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
19,078 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 Trailblazer fuel system problems

fuel system problem

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2004 Chevrolet Trailblazer Owner Comments

problem #9

Sep 152011

Trailblazer 4WD 6-cyl

  • 85,000 miles


While getting a tuneup, third party mechanic advised me that there was a crack in the neck of the gas tank, where the filler tube meets the tank itself. I was advised there was a recall on the 2003 Chevy Trailblazer for the same defect. I was also advised there was a NHTSA investigation. I was told my VIN# did not fall within the recall. The third party mechanic advised $800 to replace the tank. I called GM customer service and was told to take it to a GM dealer and have a GM certified mechanic verifiy the third party mechanic's findings. I did so and was charged by the GM dealer to verify there was a crack. When GM customer service called back and verified that there was a problem, they assigned me to a GM customer assistance representative who would investigate if they could assist me with the repairs. Approximately 10 days later I was advised that they would not be able to assist me because the problem I was experiencing was due to age and mileage of the vehicle. There are numerous reports of owners of 2004 Chevy Trailblazer owners on the internet that have experienced the exact same problem with fractured, cracked and broken connections on the gas tank where the filler tube meets the tank. I don't understand why a recall for this has not been issued. My vehicle is 7 years old and has less than 90,000 miles on it. We don't live in a state that is considered to be a "corrosive hazard state". if the same problem is happening to the same part on the same vehicle, what is keeping a recall from being issued?

- Jonesboro, AR, USA

problem #8

Mar 152008

Trailblazer 4WD 6-cyl

  • Automatic transmission
  • 33,000 miles
The contact owns a 2004 Chevrolet Trailblazer. While driving at various speeds, the check engine light illuminated and the message center informed the contact to tighten the gas cap. When he attempted to tighten the gas cap, he noticed a thin crack in the filler neck. When he fills the gas tank, there was some leakage from the crack of the filler neck. The contact has taken the vehicle to the dealer, but it was not serviced because the warranty was expired. The current mileage was 34,000 and failure mileage was 33,000. Updated 04/22/08. The pipe to the gas tank was composed of plastic. It has a crack about 1/2 inches long at the gas cap area, thus allowing vapors to escape the tank. Updated

- Evergreen, CO, USA

problem #7

Mar 012008

Trailblazer 6-cyl

  • Automatic transmission
  • 37,500 miles
2004 Chevy Trailblazer. Gas leak where the filler neck connects to the tank. I have seen many, many of these on the forums. GM has a bad design here.

- Cypress, TX, USA

problem #6

Sep 272007

Trailblazer 4WD

  • Automatic transmission
  • miles


I have a 2004 Chevy Trailblazer and from day one I've had problems with gas overflowing out of my vehicle when pumping gas in to it. I'm not trying to top off the tank, at the first click I stop pumping and gas overflows outside of the vehicle all over my car, my feet and legs and the ground. Sometimes I don't even get the warning click that it's full. It doesn't do it all the time so when I've taken it to my dealership they say they can't duplicate the problem. I've met other Trailblazer owners at the pump and they say they have the same problem. This doesn't seem safe or environmentally sound. I have had the vehicle for 4 years and have tried many different gas stations/pumps.

- North Branch, MI, USA

problem #5

Sep 152007

Trailblazer 4WD 6-cyl

  • Automatic transmission
  • 12,000 miles
When filling up with gas, it spews from the tank when gas nozzle is removed. It does not matter how much gas is in tank & happens even when tank is not being topped off. Also when filling, you must constantly reposition the nozzle because of gas build up in tank line will inadvertently cause pump to turn off. This has happened on numerous occasions, however last night was the final straw, Trailblazer had a quarter tank of gas, after pumping in less than a gallon, nozzle/pump started its clicking/auto shut off. I removed the nozzle to reposition it as usual & upon removal of nozzle gas sprayed (like spraying from a hose nozzle)from the tank as if under pressure. I was completely covered with gas from the waist down, I'm not talking about a light spray but soaked through my clothes to the skin with gas. Based on the amount of gas left on the ground I estimate that 2 or 3 gallons sprayed from the tank, the only way it was stopped was by putting the cap on. Although not seriously injured I am now covered in a rash from the gas from the waist down.

- Washington, IN, USA

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problem #4

Oct 102005

Trailblazer 4WD

  • Automatic transmission
  • 4,000 miles
I have 2004 Trailblazer and I have had the gas line replaced and adjusted several time due to unable to fill up with gas and I again took it back now they want to replace the gas tank. This is an on going problem and the warranty has just went out and I am still having these problems it will work for a few months then it wont let you fill it up any more and I have to continue ta take it in.

- Bella Vista, AR, USA

problem #3

Jan 052005


  • miles


2004 Chevrolet Trailblazer fuel filler inlet overflows upon tank fill-up. This condition occurs at fill-up when pump handle is set on automatic shut off, or when shut off occurs when manually filling. This condition is repeatable, and happens regardless of what gas station is used. This condition was reported to a local Chevrolet dealer. Their fix was to replace the inlet filler hose to the tank. This fix was unsuccessful and the condition still exists. Currently attempting to schedule another service appointment.

- Concord Township, OH, USA

problem #2

Jan 222005

Trailblazer 4WD 6-cyl

  • Automatic transmission
  • 200 miles
The gas tank always overflowes when filled. It is hard to position the nozzle into the filler neck so that gas flows without holding the pump handle and repositioning several times during the filling process. The oveflow is not from trying to top off the tank either. It happens when the tank is not even full. I have had the vehicle into the dealership more than five times for this and for electrical/battery problems in less than one year. No correction has been made.

- North Myrtle Beach, SC, USA

problem #1

Apr 102004


  • miles
Every time I fill up the gas tank (tried 10 different pumps at 10 different gas stations) the autoshut off on the gas pump does not work quick enough. Gas overflows out of the tank and spills on the ground. Something wrong with the design of the Trailblazers fill up tube? I am not trying to "top off" the tank either.

- Norwalk, CT, USA

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