Print this page Notes: The first year for Chevrolet's replacement for the S-10.


really awful
Crashes / Fires:
0 / 5
Injuries / Deaths:
2 / 0
Average Mileage:
60,962 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 Colorado electrical problems

electrical problem

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2004 Chevrolet Colorado Owner Comments (Page 1 of 4)

problem #70

Jan 012017


  • 182,000 miles


Problem # 1: had to replace the HVAC resistor and its wiring harness. Resistor plug and the harness plug was burned and hazard! this safety hazard could have burned up my vehicle. Problem #2: the ABS warning light keeps coming on and when this happens (every day or so) the brakes do not work properly. This seems to happen when the vehicle is not parked on a level surface. The fault occurs once the vehicle moves forward from the parked position.

- Richmond, IN, USA

problem #69

Oct 132010


  • 98,000 miles
The ignition key has twice needed to be replaced as the key itself seems to lose the ability to turn in the ignition. I assume that the key wears out over a period of time, but I have never had this issue with any other vehicle that I have owned. I have had to call a locksmith both times and have a new key made in order to start the vehicle. Both times I was in a parking lot.

- Raytown, MO, USA

problem #68

Jun 102015

Colorado 4WD 5-cyl

  • 130,000 miles
I too have experienced problems with the HVAC system of this truck. I have had to replace no less than 4 resistors and connectors due to melting and burned connections. I have not had to replace a single fuse. My HVAC is once again inoperable and I have opened and inspected each connection point to locate the problem. I have found multiple connectors to be burned or melted. This problem has been flagged by the nhsta in the Hummer H3 vehicles which use the same HVAC system. The Chevrolet/GMC/Isuzu Colorado/canyon (gmt355) should be included in this recall. There is no reason these connections should get hot enough to bubble and burn plastic before burning out a fuse. I can provide images upon request. I can also provide an example of a failed connector in the HVAC speed control switch for physical inspection. I have set the "fire" flag on this report as there has been evidence of multiple electrical fires on multiple occasions in several locations in the HVAC system of this vehicle.

- Rochester, NY, USA

problem #67

Oct 312007


  • 22,000 miles


Chevy Colorado trucks risk of fire! this truck is on its 3rd A/C & heat fan speed control resister and corresponding connecting plug. The first two were covered under the factory warranty, this last one was not. Each resister and plug in connector has been on the verge of catching on fire. At times you can smell smoke in the truck. If the fan speed control is on 1,2, or 3. off & 4/high work ok. Each plug has melted and is a charred black and the contacts are no longer supported by the plug. The intense heat has charred the resistors corresponding connection socket. I have photos of the resister and plug for your inspection. Upon request. And the old units for you. If you do a web search for Chevy fan or blower speed control stops working you will find this is a common problem. This connection needs to be redesigned before it burns down someone's house because they parked their car in the garage.

- Lees Summit, MO, USA

problem #66

Apr 082005


  • 141,025 miles
Vehicle was repaired at bacon Chevrolet in milledgeville, ga. I am still getting letters to the effect that it was not repaired. I personally saw new part on vehicle.

- Gray, GA, USA

problem #65

Mar 192008

Colorado 5-cyl

  • 39,994 miles
The brake light switch has failed multiple times. It was covered twice under a recall. Switches only last 1.5-2 years. There is no warning or dash light when they go out. I have almost been rear ended twice. Happened again April 13, 2015. I drove it straight to the dealer when I found out in traffic. I knew it was the brake switch again and the dealer confirmed. The dealer called GM to see if they would cover the replacement. They refused. The dealer gave me a discount as they know it is an issue and charged me $87 to change. This is the second time I have had to pay. He gave me this number to call but that was no use as they refused last time. 800-222-1020. Most concerning to me is the lack of concern by GM to fix a know safety issue in the brake and light system. Someone probably has or will be seriously injured or killed. They need to come up with a comprehensive fix and at a minimum continue covering failures under warranty. Not fixing the design problem then making money charging people is not right. The dealer who did the work last time is five star Chevy in dallas, tx. Craig greene was the representative who tried to help me with GM if you need to contact him. Dealer tried but GM did not take ownership for their product.

- Lewisville, TX, USA

problem #64

Jan 022013

Colorado 4WD 5-cyl

  • 85,000 miles


Everyday now when I try to start the truck it turns over but will not start, wait 15 minutes then it will start. Today when I tried it the first time it turned over but would not start so when I turned it off at the key it stopped then tried to start again on its own for about 8 to 10 secs. The starter turned the engine over without touching the ignition switch it then stopped for about 3 or 4 secs then tried to start on its own again without touching the key, it did this start sequence 3 times in a row. The GM passlock system is terribly defective as reported by all the reports online and I believe my problems are a result of this system.

- Puyallup, WA, USA

problem #63

Dec 032013


  • 82,000 miles
The switch which controls the fan speed for the heat and A/C quit working. The fan only works when the it is set on high.

- Mareline, MO, USA

problem #62

Oct 132014

Colorado 5-cyl

  • 136,000 miles
Airbag light is on. My truck has never been in an accident. Through research I have found that the wiring in the door breaks.

- Mesa, AZ, USA

problem #61

Jul 252008

Colorado 5-cyl

  • 73,060 miles
The dashboard lights will stop working if your driving at night and turn the car off and then turn it back on. They will not work until the car sits for a long period of time. This started soon after buying the car brand new, but the dealership couldn't find anything wrong. Second complaint, the heater/air conditioner fan had an electrical fire at where the harness plugs into the fan motor. The fan will only work on high. When I looked online at other complaints about the same problem, I unplugged the fan and noticed the plug was burnt. I have photos that I can send. It appeared the electrical fire continued down the plastic plug to where the wires are exposed. This could have been a major incident if I didn't notice it. There are a lot of complaints about this with Colorado trucks online. Also when driving at night, my dash lights and instrument lights flicker as if there is another electrical short somewhere in the wiring harness.

- Camdenton, MO, USA

problem #60

May 062013


  • miles


The ignition will not start at first. It takes multiple times in order to get the engine to turn over. Once the ignition does cause the engine to turn over, the vehicle will suddenly lose power while driving as the vehicle shuts itself off (as if the ignition has been turned off although it has not been). This has happened on multiple occasions in the course of normal driving activities, several times while crossing busy intersections which luckily has not resulted in any crashes to date, but may very well result in a potentially fatal one should it continue to occur. Engine has been tested and all systems check out, except for the ignition switch which -will- have to be replaced.

- Houston, MS, USA

problem #59

Jul 222014


  • 40,000 miles
A/C heater resistor and plastic connector for both resistor and blower motor arced and melted. Also air bag light is on.

- North Highlands, CA, USA

problem #58

May 212014

Colorado 5-cyl

  • 122,652 miles
Turn ignition to off position and park indicator light and radio stays on. Have to jiggle key to get to go off. Come out several hours later and park indicator light and radio are back on./ also, heat and air control fan only works on high speed. I was told it was a resistor, I replaced resistor and it still continues to do this. I can reach down and jiggle the resistor and it works on all speeds for a short while only. Have a friend with GMC canyon that has had this problem since his was new also.

- Louisville, KY, USA

problem #57

Apr 122014

Colorado 4-cyl

  • miles
2004 Chevrolet Colorado. Consumer writes in regards to engine and ignition switch problems. The consumer stated on April 12, 2014, the vehicle shut off while driving 30 mph. The brake pedal was hard to push and the dashboard read reduced power. After waiting three minutes, the consumer was able to re-start the vehicle. The vehicle stalled again, after driving two miles. According to the service invoice, the PCM computer was bad.

- Naperville, IL, USA

problem #56

Aug 012012

Colorado 4-cyl

  • miles
2004 Chevrolet Colorado. Consumer writes in regards to a defective ignition switch. The consumer stated, he paid to have his ignition switch replaced, and is seeking reimbursement. He stated there were times, when the vehicle would not start, and it would take anywhere from 20-30 minutes. Over several years, he took the vehicle to the dealer, explaining the problems, with trying to start the vehicle. Each time he was told by the service manager, the problem could not be diagnose. Eventually, he took the vehicle to a repair shop, and the problem was finally diagnosed and the ignition switch was replaced. He no longer experienced starting problems. However, in September 2013, he decided to trade the vehicle.

- Toms River, NJ, USA

problem #55

Dec 272013


  • 117,000 miles
The contact owns a 2004 Chevrolet Colorado. The contact stated her vehicle would stall intermittently after it was turned on. The failure was diagnosed, both the dealer and manufacturer were aware of the failure. The vehicle was not repaired. The failure mileage was 117,000.

- Independence, IA, USA

problem #54

Mar 312014

Colorado 4-cyl

  • 92,530 miles
I was making a left turn and I let the clutch out a little too fast which stalled the engine. I went to restart and engine just craned over and over would not start. That is where I almost got hit. Had to push trk thru intersection.I have had this problem with it not restarting for a few years now.I have to wait 10 minutes before restarting. It happens intermittently when I go to start it does not start. It just cranks over.the book says its an anti-theft switch.I have to wait 10 minutes before restarting.I have seen on Chevy Colorado trk sites that it is a common problem with the ignition switch.

- San Bernardino, CA, USA

problem #53

Mar 062006


  • 11,000 miles
Some times, the car will not start if the ignition key lock light blinks. I have to wait ten minutes so that it starts I have taking it to the dealer and they have said that it has a faulty ignition housing, of course they want to charge me a lot to fix it. I believe is a factory defect. My truck has a salvage title, so the warranty on it was voided. I have heard of other Chevy Colorado trucks with same problem.

- Arleta, CA, USA

problem #52

Jun 172009


  • 34,000 miles
With the revelation of the GM ignition recall problem, there are much more ignition problems that were not included in the recall. The problem is in the ignition cylinder and alignment with the passlock or passkey sensor. My problem started shortly after the vehicle went out of warranty and I was told by the dealer that it was a $1000 repair. I can not afford $1000. So I have lived with it. Because of the misalignment it causes the ignition to think that the vehicle is stolen and disables the fuel injectors, it has left me stranded quite a few times along the road waiting for the computer to manually reset after 10 minutes, it has also cost me several towing bills until I did an internet search and found out how widespread this issue is. If the misalignment is causing this to happen what will it affect as the problem worsens. This issue is not covered by the current recall but deserves investigating. [xxx] information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- Oil City, PA, USA

problem #51

Dec 162013

Colorado 5-cyl

  • 111,234 miles
This incident occurred twice. It involves the heater blower motor resistor assembly. 8 years ago my daughter used put her back pack on the passenger floor where it repeatedly made impacted the connection to the blower motor relay assembly. This eventually caused the pin and socket on the orange wire to separate to the point where it arced and burnt. I found and repaired the socket when the heater would only work on high. On the 16th of Dec 2013, a passenger size 12 shoes accidentally, and unwittingly kicked the same spot and caused the same fault. I repaired the socket again. My complaint is the resistor connection is in a spot to easily service, but it is in a vulnerable spot for accidental contact. I believe it needs a robust protective cover, either metal or plastic. For people that cannot repair their own vehicles, this situation could cost them a couple of hundred dollars. My other electrical fault is the right side window motor. It quit working couple of years ago, and I was able to take it apart and clean the brushes. It worked for a couple of years until it stopped a couple of weeks ago. I replaced the motor because I could not find brushes to replace. I am convinced that the brushes failed because they were made brittle from slamming the doors too hard by the passengers. The doors are light and it is common for them to slammed. The brushes or the motor need to be more robust.

- El Paso, TX, USA

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