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


really awful
Crashes / Fires:
1 / 0
Injuries / Deaths:
1 / 0
Average Mileage:
63,318 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 (Page 1 of 4)

problem #70

Jun 012016


  • miles


2004 Chevrolet Trailblazer. Consumer writes in regards to customer relationship specialist dismissive and premature file closure of defective vehicle fuel tank inlet check valve fracture problem with no current repair solutions.

- Boulder, CO, USA

problem #69

Dec 012015

Trailblazer 6-cyl

  • miles
2004 Chevrolet Trailblazer. Consumer writes in regards to fuel tank inlet check valve mileage restrictions repair issues. The dealer would not honor the special coverage adjustment program, because the consumer's vehicle had high mileage.

- Oregon, OH, USA

problem #68

Sep 022013

Trailblazer 6-cyl

  • 109,167 miles
Was constantly having the service engine light soon come on. Went to my repair shop and they said I needed to replace my gas cap. They reset the sensor and replaced my gas cap. Same thing happened on and off over the last 9 months. On July 18th it happened again. Took it to different shop and they performed a smoke test and found a crack in the gas tank where the filler tube is, so when the gas tank is full it leaks or when you corner. Not a lot but I would assume that any would be bad considering the exhaust pipe is right there. Looking online I found NHTSA already had an item regarding this issue its number is PE07014. I contacted Chevy and was told that my VIN number was not attached to the action but it is the same issue that was noted on the NHTSA action notice and research I performed on the web. Did they tell you that they were only going to cover certain VIN. I could not find this anywhere on your site. But could have missed it.

- San Jose, CA, USA

problem #67

Nov 012012

Trailblazer 6-cyl

  • 95,000 miles


I first starting smell gas out side the Trailblazer after filling it up. I looked at the fuel tank and looks to be leaking at the filler neck. Now I am smell gas coming through the vents inside the vehicle.

- Tupelo, MS, USA

problem #66

Sep 092013

Trailblazer 6-cyl

  • 176,313 miles
Check engine light came on, when it was checked it showed there was a large E-vap leak. When pressure test was done on system fuel started coming out of hose going into top of fuel tank. Was told there was a major recall on this part. However because I exceeded the mileage by 20,000 mi GM will not cover damage. This is a major safety problem and I was never notified of this problem like I think GM should have. I believe GM should re-imburse any out of pocket funds owner spends to fix problem and make vehicle safe again.

- Aptos, CA, USA

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problem #65

Aug 192013

Trailblazer 6-cyl

  • 124,000 miles
Failed emissions testing due to evap error code. My 2004 Chevy Trailblazer was taken to the mechanic who performed a smoke test and identified a small leak at the fuel tank inlet. He was aware of the issue and printed out a 'special coverage adjustment - fuel tank inlet check valve fracture # xxxxx - (08/24/2007) ' and advised me to take it to the dealer. He also advised me that my VIN was not on the list but the problem is the same as identified by others on multiple other forums on the internet and the printout. Dealer refused to do the warranty work citing the fact my VIN was not on the list. I contacted GM and am escalating the issue. The smell of gasoline is more pervasive than ever before!

- Tempe, AZ, USA

problem #64

May 012013

Trailblazer 6-cyl

  • 105,000 miles


Fuel tank is leaking fuel from top of tank. Strong smell of gas outside and inside vehicle. Drips down side of tank when driving. Repair is over $1000 dollars. Internet is full of same complaints. Why is there no action recalling this public hazard? vehicle is ext extended version. Called GM and they say they have no knowledge of problem. Despite an earlier notice.. this Agency needs to be more accountable. This is what happens when the government owns the business they are to regulate. Shame. Read your complaints and take action.

- Myerstown, PA, USA

problem #63

Jan 012010


  • 80,000 miles
The contact owns a 2004 Chevrolet trail Blazer. The contact stated that after refueling, the smell of gasoline fuel was emitted inside of the vehicle. The check engine warning light was also illuminated during the failure. The vehicle was taken to a private mechanic where the mechanic confirmed that the fuel tank needed to be replaced due to a leak. The manufacturer was not contacted. The vehicle was not repaired. The failure mileage was 80,000 and the current mileage was 99,000.

- South West Ranches, FL, USA

problem #62

Sep 012011


  • 110,000 miles
The contact owns a 2004 Chevrolet Trailblazer. The contact stated that after refueling, fuel would spill out from the filler neck. The vehicle was taken to a dealer where they advised her that there was a hole in the fuel tank and the filler was fractured. The entire fuel tank would need to be replaced. The vehicle fuel tank was replaced. The manufacturer was not made aware of the failure. The failure mileage was approximately 110,000.

- Surf Side, SC, USA

problem #61

Jul 122011


  • 103,000 miles
The contact owns a 2004 Chevrolet Trailblazer. The contact stated that there was a fracture in the fuel neck line, causing a fuel leak. The contact took the vehicle to the dealer where the dealer stated to the contact that the fuel tank needed to be replaced. The vehicle was not repaired. The failure mileage was 103,000.

- Florence, AZ, USA

problem #60

Feb 172011

Trailblazer 6-cyl

  • miles


General Motors vehicle is showing an incorrect speed, the speedometer stops working, the tachometer needle sticks or stops working, the fuel gauge flutters or the entire instrument panel fails.

- Henderson, NV, USA

problem #59

Mar 162011

Trailblazer 6-cyl

  • 37,820 miles
We have a low mileage 2004 Chevy trail Blazer (under 45,000 miles as of September 2011). In March 2011, the check engine light illuminated. We had the oil changed and tried some fixes with the battery cables. All reset the engine light, but each time the light would again illuminate after several days had passed. In August 2011, we took it to Texas auto service to have them test the engine light sensor and we then paid for them to replace the canister vent solenoid. Once again, the light turned off for a period of days and then came back on. In late September we took it to Firestone - and after 2 days of testing, it was determined that the fuel tank had a crack. We then picked it up from Firestone and took it to bankston Chevrolet in ft worth - after another day of testing, they concurred and we were forced to pay $1336.18 to have the fuel tank replaced... otherwise we ran the risk of a fire. We did research and find that many of the GM trucks have had recalls on this specific failure - but not our specific year/model and VIN number.

- Keller, TX, USA

problem #58

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 #57

Oct 092011

Trailblazer 4WD 6-cyl

  • miles
2004 Chevy Trailblazer fuel gauge not working it goes around in circles does not measure fuel and has caused vehicle to run out of gas, the gauge started measuring incorrectly, then moving from full to empty going in circles now its stuck arrow pointing downward, my family and I were lucky that the vehicle behind us was not speeding or else he would have slammed into the back of our SUV and caused a serious accident.

- El Paso , TX, USA

problem #56

Sep 272011


  • 125,000 miles
The contact owns a 2004 Chevrolet Trailblazer ls. The contact noticed after refueling the vehicle to capacity, the fuel would leak onto the ground. The vehicle was taken to an independent mechanic who informed the contact that the top portion of the fuel tank was fractured. The vehicle was not repaired and the manufacturer was notified of the problem. There was a technical service bulletin pertaining to the defect under NHTSA item number 10026522 (fuel system, other:storage:tank assembly). The approximate failure mileage was 125,000.

- Weston, FL, USA

problem #55

Feb 012011

Trailblazer 6-cyl

  • miles
My head lights don't come on randomly. Randomly they do. Obviously, this is a serious safety issue especially at night. No, it's not light bulb replacemet issues.....other blog sites have complained about the same issues. Very dangerous!!!! the gas gauge also is not working properly. When the gas gets low it blinks on for a second then adds more gas to the panel. People could run out of gas unknowingly. Also very dangerous!

- Columbus, OH, USA

problem #54

Jul 102011

Trailblazer 6-cyl

  • 102,103 miles
Faulty fuel sending unit: Causing fuel gauge to not read correctly or all together. Would like to replace but don't have the $600 quoted by the dealer.

- New Braunfels, TX, USA

problem #53

Aug 162011

Trailblazer 4WD 6-cyl

  • 100,000 miles
Instrument panel failure, ran out of gas on a busy four lane highway during morning rush hour. I was in the left hand lane and was unable to move to the shoulder. I now became a major traffic problem until some nice citizen helped me push the truck out of harms way, having to stop both lanes of traffic so I could cross. Had I a working gas gauge I feel this would not have happened, none of the instruments in the vehicle work, Chevy has recalled other models of this year with the same problems, but not the Trailblazer. Why?

- Lakeland, FL, USA

problem #52

Jan 012010

Trailblazer 4WD 6-cyl

  • 60,000 miles
Crack in fuel tank 2004 Chevy Trailblazer ls. Crack is just below where the filler tube goes into tank. I have researched online and find that this is a common problem but there is no recall. I am concerned about a fire and explosion. A new fuel tank from the dealer is over $1000. I have tried to patch it but it is made of a special plastic that is herd to repair.

- Omaha, NE, USA

problem #51

Apr 142011

Trailblazer 4WD 6-cyl

  • 103,000 miles
2004 Chevy Trailblazer ls 4WD. I had noticed a strong smell of gasoline. About two days later my service engine soon light came on. I took it to a mechanic to have it checked out and was told that there was an evaporative leak detected according to the codes that the computer was giving. The mechanic then checked the vehicle further and notice that there was a hairline fracture in the fuel tank near the filler nozzle. I was told that this was a very common problem with this vehicle and he told me to contact Chevy for a possible recall. I did contact Chevy and was told there was no recall but I could take it to a Chevy dealership and have it fixed at my expense. I can not even park this vehicle in my garage for risk of a fire and the vehicle can not pass emissions inspection because it has a leak. I have received a citation for failure to inspect because it wont pass the inspection process. It will cost me approx $800 to have this fixed.

- Joshua, TX, USA

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