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hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
54,133 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 Tahoe fuel system problems

fuel system problem

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2004 Chevrolet Tahoe Owner Comments

problem #6

Nov 132013

Tahoe 8-cyl

  • 59,000 miles


Approx. 6 months ago I was driving when a vehicle entered the intersection in front of me. I stepped on the brakes and the pedal went to the floor. Luckily there was no crash but my vehicle just barely came to a stop. Towed the vehicle to a dealership and found all the brake lines were rusted out and needed to be replaced. On 3/28/14 I began noticing strong gas fumes coming from my vehicle. I again took it it in and found the fuel pump assembly, all the fuel hoses, and the straps and bolts that hold the fuel tank were rusted out. I read that NHTSA was doing a study of this issue. I understand my vehicle is 10 years old and I live in the northeast but I observed a lot of rust under my vehicle. I am a police officer and a crash reconstructionist and these rust issues could cause serious issues with vehicles resulting in crashes. I feel this issue needs to be investigated because it effects crucial systems like the brakes and fuel systems. Please feel free to contact me for further information.

- Bordentown , NJ, USA

problem #5

Feb 092006

Tahoe 8-cyl

  • 7,000 miles
My wife and I bought the vehicle new. It was always kept in a garage and driven very little. As of today it only has 30,000 miles on it. To begin with, on or near March 2007 after exiting the vehicle I noticed a strong smell of gasoline. I looked under the car and I saw a fairly heavy dripping of gas from the top of the gas tank. I drove it to a mechanic that I have been using for many years. He told me that he had a hard time finding where the gas was coming from but with a mirror, he was able to see that it was coming from the fuel pump or what he called the fuel sending unit. He said it appearred to be coming from the pump in thr top of the tank and that it was badly rusted and needed to be replaced. I called the dealer from who we had bought the Tahoe and asked if there were any recalls to this. They said no. I should also tell you that the mechanic told me that he had replaced many of this same tanks. He said it was built in such a way as to be shaped like a bowl and that the water just laid in it. It cost me $750 to get a new fuel sending unit put in. About 4 years later, the exact same thing happened. The entire top of the pump was rusted out and again gas leaked out. Enough gas leaked out to almost cover my entire garage floor. This really kind of scared me. Even just any kink of a small spark and not only me but my hole house with five other people not might of got hurt, with this much gas we would have been dead.. again I checked for recalls of which there were none and ended having again a new fuel pump installed. The only difference being that he.

- Mogadore, OH, USA

problem #4

Aug 302011

Tahoe 4WD 8-cyl

  • 62,800 miles
Smell of fuel for about a week brought it to evans automotive St Aug. Fl. 32080. They contacted me and told me flaw in design of tank water gets up on top of tank and sits there. This rots out sending unit and fuel pump as well as locking studs that hold down this one piece unit.tank is plastic but studs that lock in part are metal they rot making tank very very dangerous. They said I was very lucky the truck did not catch fire with my family and I in it. They said the smallest spark would have caused the truck to catch fire. To repair this it is going to run about $1500, or try to find a used tank in good shape. They are telling me weather new or used this is going to happen again over time. The flaw is that there is no way for water to get out of bowl shape where fuel pump is. That makes it very dangerous. When looking for tank it says tank from 2003 to 2009 fit. That means other trucks have same problem such as Chevy, GMC, pickups, Sierra, silverdos, Yukon ect. Please look into this before someone or some family gets killed. Thank you!

- St Augustine, FL, USA

problem #3

May 072011


  • 140,000 miles


The contact owns a 2004 Chevrolet Tahoe. The contact stated while driving approximately 75 mph she heard a clicking noise followed by the illumination of the anti-lock brake and fuel gauge warning lights on the instrument panel. Moments later the vehicle stalled. Upon restart the vehicle operated as normal. The failure recurred approximately twenty times within a two week period. The vehicle was taken to an independent mechanic where they were unable to diagnose the failure. The contact planned on taking the vehicle to an authorized dealer to have the failure diagnosed. The contact also expressed concern of NHTSA campaign id numbers: 04V045000 (fuel system, gasoline), 04V045000 (service brakes, hydraulic) and 07E106000 (wheels: Cap/cover/hub, which he believed could have possibly contributed to the failure. The VIN was not included in any of the recalls and the vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was 140,000.

- West Cliffe, CO, USA

problem #2

Oct 152007


  • 15,000 miles
I bought new a 2004 Chevy Tahoe. It is kept garaged 99% of its life. About 2 years ago I started smelling gasoline on windless days whenever I would exit the car after any trip. At the time in 2006 I thought it was almost impossible for there to be a gas line that was rusted and I thought that somehow a line must have cracked. I went to my mechanic and had him check it out. He called me the next day and told me that the gasoline right where they exited the fuel tank were badly rusted and thats where the gas was coming from. He brought me into his shop and with the car up in the air, he was able to show me using 2 mirrors because it wasn't possible to see by looking up as to how badly the 3 lines had rusted. At this time the car only had about 12000 miles on it. He explained to me that where the fuel lines came out of the tank that it was shaped like a bowl and that even if I was just washing it, there would still be a fairly large puddle of water there. This car was my pride and joy. I never drove it in wet weather and I never drove it during the winter. I was shocked to see how much gas was coming out and my first thoughts were that one spark with all those fumes and gas and I'd be a dead man. I always kept the gas tank full, it never went below 2/3 of a tank. My mechanic told me that he had repaired 7 or 8 of these on other Chevrolet large SUV's including a couple other Tahoe a couple Suburban and 2 or 3 denali's. he told me that he couldn't remember which but he was aware that these other cars were covered by a recall but that for some reason the Tahoe wasn't even though they all had the same gas tank. I should not have put off writing this letter. At any rate it cost me $750 to get it repaired and I'm just waiting for it to happen again. This seems very much like a design problem. I have to wonder why the Tahoe was not included in any recall as the are all the same.

- Mogadore, OH, USA

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problem #1

Aug 092005

Tahoe 8-cyl

  • Automatic transmission
  • 41,000 miles
The gas gauge module was faulty, causing me to run out of gas at high speed and lose power to steering and brakes. Out of gas even though it read that I had a quarter of a tank. Luckily no accident or damage done. However it cost $650 to replace this module.

- Liberty, SC, USA

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