2004 CHEVROLET W3500 — Problems, Recalls & Safety Data
N/A
Safety Rating
9
Owner Complaints
1
Recall
0
Service Bulletins
0
Investigations
Overview of the 2004 CHEVROLET W3500
The 2004 CHEVROLET W3500 has received a total of 9 safety complaints filed with the National Highway Traffic Safety Administration (NHTSA). There has been 1 recall campaign affecting this vehicle, covering issues with FUEL SYSTEM, DIESEL:STORAGE:TANK ASSEMBLY. The most commonly reported problems involve the Electrical System (1 complaint), Engine And Engine Cooling (1 complaint), and Engine And Engine Coolingexhaust System (1 complaint).
Recalls for the 2004 CHEVROLET W3500
NHTSA has recorded 1 recall for the 2004 CHEVROLET W3500, potentially affecting up to 253 vehicles.
Recall 05V168000 — FUEL SYSTEM, DIESEL:STORAGE:TANK ASSEMBLY
| 253 vehicles affected
Defect: ON CERTAIN TRUCKS EQUIPPED WITH RPO IK9, DUE TO INSUFFICIENT DURABILITY AND TESTING, THE FUEL SWITCHING MANIFOLD SOLENOIDS LACK WATER OR SALT INTRUSION RESISTANCE, WHICH CAN LEAD TO FAILURE OF ONE OR MORE SOLENOIDS. FUEL SWITCHING MANIFOLD SOLENOID FAILURE WILL CAUSE INCORRECT FUEL DELIVERY RESULTING IN FUEL OVERFLOW FROM THE FUEL FILLER NECK.
Consequence: OVERFLOW FUEL MAY RESULT IN HIGH AMOUNT OF DIESEL FUEL LEAKAGE. FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
Remedy: DEALERS WILL REPLACE THE SOLENOID VALVE ASSEMBLY WITH AN IMPROVED ASSEMBLY INCLUDING ADDITIONAL DETECTION CIRCUIT AND ENHANCED WATER RESISTANCE FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 27, 2005. OWNERS MAY CONTACT ISUZU AT 1-800-255-6727.
View full details →Owner Complaints for the 2004 CHEVROLET W3500
9 complaints have been filed with NHTSA for the 2004 CHEVROLET W3500. Below is a breakdown by vehicle component.
| Component | Complaints | Crashes | Fires | Injuries | Deaths |
|---|---|---|---|---|---|
| Electrical System | 1 | 0 | 0 | 0 | 0 |
| Engine And Engine Cooling | 1 | 0 | 0 | 0 | 0 |
| Engine And Engine Coolingexhaust System | 1 | 0 | 0 | 0 | 0 |
| Engine And Engine Coolingexhaust Systemmanifoldheadermufflertail Pipe | 1 | 0 | 0 | 0 | 0 |
| Fuel System Gasolinedeliveryfuel Pump | 1 | 0 | 0 | 0 | 0 |
| Fuel System Gasolinedeliveryhoses Linespiping And Fittings | 1 | 0 | 0 | 0 | 0 |
| Service Brakes Hydraulicfoundation Components | 1 | 0 | 0 | 0 | 0 |
| Structure | 1 | 0 | 0 | 0 | 0 |
| Suspensionrearshock Absorber | 1 | 0 | 0 | 0 | 0 |
Most Recent Complaints
THE BOLTS ATTACHING THE EXHAUST MANIFOLD TO THE ENGINE ARE BROKEN OFF CAUSING EXHAUST LEAKS BOTH SIDE MOTOR. THE CAB OF THIS VEHICLE SITS OVER THE MOTOR SO YOU CAN SMELL RAW EXHAUST INSIDE THE VEHICLE.. THERE ARE SEVERAL COMPLAINTS POSTED ONLINE AND YOUTUBE ABOUT THIS PROBLEM. I HAVE A FRIEND THAT HAS A SIMILAR TRUCK TO MINE AND HE HAS SAME PROBLEM. *TR
THE BOLTS ATTACHING THE EXHAUST MANIFOLD TO THE ENGINE ARE BROKEN OFF CAUSING EXHAUST LEAKS BOTH SIDE MOTOR. THE CAB OF THIS VEHICLE SITS OVER THE MOTOR SO YOU CAN SMELL RAW EXHAUST INSIDE THE VEHICLE.. THERE ARE SEVERAL COMPLAINTS POSTED ONLINE AND YOUTUBE ABOUT THIS PROBLEM. I HAVE A FRIEND THAT HAS A SIMILAR TRUCK TO MINE AND HE HAS SAME PROBLEM. *TR
TL*THE CONTACT OWNS A 2004 CHEVROLET C3500 TRUCK. THE CONTACT STATED THAT THE EXHAUST SYSTEM IS LEAKING. FUMES EMITTED THROUGHOUT THE CABIN WHEN THE ENGINE WAS IN OPERATION. THE CONTACT WAS IN THE PROCESS OF PERFORMING A DIAGNOSTIC TEST TO DETERMINE THE CAUSE OF FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 152,000. UPDATED 05/24/11*LJ THE CONSUMER STATED THE VEHICLE HAS A CRACKED EXHAUST MANIFOLD. UPDATED 05/26/11
TL*THE CONTACT OWNS A 2004 CHEVROLET C3500 TRUCK. THE CONTACT STATED THAT THE EXHAUST SYSTEM IS LEAKING. FUMES EMITTED THROUGHOUT THE CABIN WHEN THE ENGINE WAS IN OPERATION. THE CONTACT WAS IN THE PROCESS OF PERFORMING A DIAGNOSTIC TEST TO DETERMINE THE CAUSE OF FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 152,000. UPDATED 05/24/11*LJ THE CONSUMER STATED THE VEHICLE HAS A CRACKED EXHAUST MANIFOLD. UPDATED 05/26/11
VEHICLE WAS TOWING A TRAILER. WHEN THE LEFT REAR SHOCK MOUNT BROKE OFF THE AXLE. THE BRAKE LINE IS BOLTED TO THE SHOCK MOUNT. WHEN THE MOUNT BROKE, IT TOOK OUT THE BRAKE LINE, WATCH RESULTED IN THE LOSE OF BRAKES. AFTER HAVING A WELDER LOOK AT THE BRACKET WE CAME TO THE CONCLUSION THAT THE WELDS FROM THE FACTORY WERE TO COLD TO PENETRATE THE BRACKET OR THE AXLE. WE PUT NEW BRAKE LINE ON AND REMOUNTED THE SHOCK BRACKET TO AXLE. WE REROUTED THE BRAKE LINE SO IT WAS NOT ON THE SHOCK MOUNT.
Safety Rating for the 2004 CHEVROLET W3500
NHTSA has not yet tested the 2004 CHEVROLET W3500 in its New Car Assessment Program.
Technical Service Bulletins for the 2004 CHEVROLET W3500
No technical service bulletins have been reported for this vehicle.
NHTSA Investigations for the 2004 CHEVROLET W3500
There are no NHTSA defect investigations on record for this vehicle.
Other Model Years of the CHEVROLET W3500
- 1999 CHEVROLET W3500 — 0 complaints
- 2001 CHEVROLET W3500 — 2 complaints
- 2003 CHEVROLET W3500 — 4 complaints
- 2004 CHEVROLET W3500 (current)
- 2005 CHEVROLET W3500 — 5 complaints
- 2006 CHEVROLET W3500 — 4 complaints
- 2007 CHEVROLET W3500 — 3 complaints
- 2008 CHEVROLET W3500 — 0 complaints
- 2009 CHEVROLET W3500 — 0 complaints
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