2004 Chevrolet Silverado 3500

Defect. CERTAIN REPLACEMENT FUEL FILTERS, FRAM BRAND NAME P/N G3727, WITH DATE CODES X52911 THROUGH X60801 SEQUENTIALLY OR X600141 AND A MEXICO COUNTRY OR ORIGIN MARKING ON THE FUEL FILTER HOUSING MANUFACTURED FROM OCTOBER 18, 2005, THROUGH MARCH 21, 2006, SOLD FOR USE ON THE VEHICLES LISTED ABOVE AND ON CERTAIN SCHOOL BUSES. (TO SEE THE SCHOOL BUS ENGINE SIZES, CLICK ON "DOCUMENT SEARCH" AND THEN "BUS APPLICATIONS"). THE CONNECTOR ON THE FUEL FILTER WAS NOT MANUFACTURED TO HONEYWELL'S SPECIFICATION. AS A RESULT, THE O-RING MAY NOT SEAT CORRECTLY ON THE FUEL LINE.

Risk. THIS CONDITION MAY CAUSE AN INADEQUATE SEAL AT THE CONNECTION, POTENTIALLY LEADING TO A FUEL LEAK. IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.

Remedy. HONEYWELL WILL NOTIFY OWNERS AND REPLACE THE FUEL FILTERS FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 18, 2006. OWNERS MAY CONTACT FRAM CUSTOMER SERVICE AT 1-800-890-2075 (OPTION 1).

ALL FACTORY HARD BRAKE LINES HAVE FAILED DUE TO CORROSION. I'VE REPLACED THE INTERMEDIATE LINE BETWEEN THE MASTER CYLINDER AND DISTRIBUTION BLOCK WITH STAINLESS STEEL 1.5 YRS AGO. I JUST REPLACED THE REAR BRAKE LINES ALONG THE AXEL. NOW THE FRONT BRAKE LINES HAVE FAILED. IN ALL CASES THE LINES FAILED WHILE DRIVING AND EMPTIED THE MASTER CYLINDER. I DO NOT LIVE IN THE SALT BELT.

BRAKE LINE FAILURE DUE TO RUSTED & CORRODED BRAKE LINES RESULTING IN COSTLY REPAIRS. LUCKILY MY 2004 CHEVY SILVERADO 3500 WAS STATIONARY WHEN BRAKE LINE RUPTURED AND I WAS NOT TOWING A TRAILER OR LOADED WITH CARGO AT THE TIME OF FAILURE. THE ABS PUMP ALSO FAILED PRIOR TO LINE FAILURE. MY FATHER IN LAW HAD SIMILAR ISSUES WITH THE SAME MODEL YEAR 1500. WHY DOES GM NOT USE STAINLESS BRAKE LINES FOR SUCH AN IMPORTANT SAFETY COMPONENT.

2 PROBLEMS: 1- WHILE DRIVING WITH NO WARNING THE BRAKES FAILED. AFTER COASTING TO A STOP I NOTICED A BRAKE LINE HAD RUPTURED AT THE FRAME RAIL UNDER DRIVER AREA. I WAS ABLE TO CRIMP BRAKE LINE WITH A PAIR OF VICE GRIP PLIERS AND MOVE TRUCK TO A SAFE LOCATION FOR REPAIR. I BELIEVE THE BRAKE LINES USED ON THESE TRUCKS TO BE OF SUCH INFERIOR QUALITY THAT SUDDEN FAILURE IS A COMMON OCCURRENCE. 2- MY TRUCK HAS DUAL TANKS FOR DIESEL FUEL AND THEY HAVE WORKED SPORADICALLY FOR YEARS. I DID NOT SEE THIS AS A SAFETY ISSUE AS MUCH AS AN INCONVENIENCE. HOWEVER WHILE MY TRUCK WAS IDLING ON A HOT SUMMER DAY I NOTICED DIESEL FUEL DRIPPING OUT OF THE FRONT TANK FILLER CAP. APPARENTLY THE PUMP THAT PUMPS THE FUEL FROM THE REAR TANK TO THE FRONT TANK WAS RECEIVING A SIGNAL TO PUMP EVEN THOUGH THE FRONT TANK WAS COMPLETELY FILLED. IT WAS CONTINUING TO PUMP AND LEAKING THE FUEL OUT THE FILLER NECK. THIS SEEMS LIKE A SERIOUS SAFETY HAZARD TO ME. I DO NOT KNOW IF THE ROOT OF THE PROBLEM IS THE FLOAT THAT STICKS IN THE REAR TANK, THE SENDING UNITS THAT FAIL, A WIRING GROUND ISSUE OR SOME OTHER ELECTRONIC GLITCH. I DO KNOW ISSUES WITH DUAL TANK DURAMAX DIESEL TRUCKS ARE ABOUT AS COMMON AS THE TRUCK ITSELF IS. AFTER RESEARCHING ONLINE I REALIZED MANY OTHER OWNERS OF MY VEHICLE MODEL HAVE HAD BOTH OF THE EXACT SAME PROBLEMS SO I THOUGHT I SHOULD REPORT THEM.

TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 3500. THE CONTACT STATED THAT THE ROCKER PANELS LOCATED UNDER THE DOORS ON BOTH THE DRIVER AND PASSENGER SIDE OF THE VEHICLE WERE RUSTED AND CORRODED. THE VEHICLE WAS TAKEN TO THE DEALER WHO DID NOT REPAIR THE VEHICLE. THE CONTACT INDICATED THAT THE STEEL INSIDE THE ROCKER PANEL WAS NOT PAINTED AND CONTRIBUTED TO THE RUSTING. THE CAUSE OF THE FAILURE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN WAS NOT AVAILIABLE. THE FAILURE MILEAGE WAS 40,000.

FRONT BRAKE LINES FAILED CAUSING FLUID LOSS AND COMPLETE LOSS OF BRAKES. HAPPENED AT SLOW SPEED, BUT STILL WAS UNABLE TO STOP BEFORE HITTING A FIXED OBJECT

IN MARCH WHILE DRIVING MY 2004 CHEVY 3500 DIESEL TRUCK THE BRAKE WARNING LIGHTS INSIDE THE CAB LIT UP AND THE BRAKE PEDAL WAS FEELING SPONGY. I TOOK IT INTO CLASSIC AUTO GROUP MENTOR FOR SERVICE. A WHEEL BEARING WAS REPLACED ALONG WITH A FEW OTHER ITEMS AND I WAS TOLD THAT IT WAS GOOD TO GO. I PICKED IT UP. THE BRAKE PEDAL WAS STILL SPONGY AND THE WARNING LIGHTS WERE STILL ON. ON APRIL 22, I RETURNED TO THE CLASSIC AUTO GROUP CHEVY SERVICE TO AGAIN HAVE THE BRAKES SERVICED. THEY BILLED ME $1400.00 TO CHANGE A VALVE, A MODULE AND SOME SCREWS. THE BRAKES NOW GO ALL THE WAY DOWN TO THE FLOOR WHEN DEPRESSED WITH THE MOTOR RUNNING. THERE IS NO EFFECTIVE BRAKING ABILITY. WITH NO EFFECTIVE BRAKING THE WARNING LIGHTS ARE NOT LIT UP. CLASSIC AUTO GROUP CHEVY IN MENTOR SAYS THAT THIS IS NORMAL. THIS IS NOT HOW THE BRAKES WORKED BEFORE THE WARNING LIGHTS CAME ON. THEY WORKED LIKE BRAKES ON ANY VEHICLE. CLASSIC AUTO GROUP MENTOR SAYS THAT I SHOULD JUST GET USED TO IT. I HAVE A COMPLAINT NUMBER FROM CHEVY # [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

TICKING UNDER HOOD. EXHAUST LEAK DUE TO BROKEN EXHAUST MANIFOLD BOLT PASSENGER SIDE NEAR FIREWALL. TRIED TO LOOSEN OTHER BOLTS, 3 MORE BROKE. TRUCK HAS VERY LOW MILES, 8.1L MOTOR. INTERNET SHOWS THOUSANDS OF SAME ISSUES. BOLTS USED ARE VERY THIN FOR WHAT THEY DO. *TR

2004 CHEVROLET SILVERADO 3500. CONSUMER WRITES IN REGARDS TO ENGINE INJECTORS ISSUE. *SMD THE CONSUMER STATED THE INJECTORS WERE REPLACED IN 2010, AND NOW THEN NEED TO BE REPLACED AGAIN.

I WAS COMING HOME FROM WORK THIS EVENING AND WAS PULLING UP TO THE GARAGE AND THE BRAKES FAILED CAUSING ME TO HIT THE GARAGE. I WAS TRAVELING LESS THAN 5 MPH. THE BRAKE PEDAL WENT ALL THE WAY TO THE FLOOR AND THE VEHICLE WOULD NOT STOP. AFTER GETTING OUT OF THE VEHICLE FOUND BRAKE FLUID ALL OVER THE DRIVEWAY. BRAKE LINES WAS FOUND TO BE RUSTED IN TWO IN SEVERAL PLACES AFTER HAVING A FRIEND WHO IS A MECHANIC COME AND LOOK AT VEHICLE. HE FOUND A COUPLE LINES THAT HAD EXPLODED THRU RIGHT UNDER THE DRIVERS SIDE SEAT ON TOP THE FRAME AND ANOTHER ONE ABOVE THE FUEL TANK. AFTER GOOGLING WHAT HAD HAPPENED THERE THOUSANDS OF COMPLAINTS WITH NHTSA ON THIS PROBLEM WITH GM VEHICLES. WHY ARE WE PAYING YOU PEOPLE TO TRY AND KEEP THE PUBLIC SAFE. THIS IS A VERY ONGOING PROBLEM WITH GM VEHICLES AND NEEDS ADDRESSED PROMPTLY. *JB

HAD JUST HOOKED UP OUR 38' - 12,000LB FIFTH WHEEL AND HEADED OUT FOR THE WEEKEND. CAME TO THE FIRST STOP SIGN AND THE BRAKE PEDAL WENT TO THE FLOOR. LUCKILY GOT STOPPED WITH TRAILER BRAKES. AFTER STOPPING, PUMPING BRAKES CAUSED BRAKE FLUID TO POUR OUT FROM JUST IN FRONT OF THE DRIVER'S SIDE REAR WHEEL. UPON RESEARCH WHEN WE ARRIVED HOME, I FIND THAT THIS IS AN ONGOING ISSUE WITH CHEVROLET TRUCKS.

BRAKES FAILED. CHINA MADE STEEL BRAKE LINES RUSTED OUT AND DISINTEGRATED. COULD HAVE BEEN KILLED. HAD TO GET REPAIR TO STEEL BRAKE LINES FROM ABS PUMP TO MASTER CYLINDER AND FRONT CALIPERS. ALSO MAKE UP AND REPLACE STEEL BRAKE LINE TO REAR AXLE AND TO REAR LEFT AND RIGHT REAR CALIPERS. ALSO HAD TO REPLACE BLEED SCREWS IN ALL CALIPERS. *TR

WHILE DRIVING MY CHEVY SILVERADO 3500 DUALLY AT APPROXIMATELY 50 MPH, I HAD SO MAKE A SUDDEN EMERGENCY STOP. MY BRAKE PEDAL WENT TO THE FLOOR WITH VIRTUALLY NO STOPPING POWER FOR THE VEHICLE. I SWERVED OUT OF THE WAY TO AVOID AN ACCIDENT AND WAS VERY LUCKY. THE TRUCK WENT DIRECTLY TO THE REPAIR SHOP WHICH HAS INFORMED ME THAT THE BRAKE LINES ARE RUSTED THROUGH AND ALL NEED TO BE CHANGED. I CALLED THE CHEVY SUPPORT NUMBER TO REPORT THIS PROBLEM AND ASK ABOUT A RECALL. THE REP TOOK THE LAST EIGHT OF MY VIN NUMBER AND SAID THERE IS NO KNOWN PROBLEM WITH THE BRAKES ON THIS VEHICLE. I TOW HEAVY EQUIPMENT WITH THIS TRUCK FOR WORK, SO IT IS AN ALARMING SAFETY CONCERN FOR ME FOR THE BRAKES TO SUDDENLY NOT WORK WITHOUT WARNING. I AM LUCKY THAT NOBODY GOT KILLED DUE TO THIS PROBLEM. *TR

COUNTY ROAD (THANK GOODNESS). DRIVING ABOUT 45 MPH WHEN A LADY TURNED OFF A SIDE ROAD IN FRONT OF ME. I STEPPED ON THE BRAKE PEDAL TO AVOID A REAR END COLLISION. THE BRAKE PEDAL HELD MOMENTARILY BUT THEN WENT TO THE FLOOR. I SWERVED RIGHT INTO THE DITCH AND USED THE EMERGENCY BRAKE TO KEEP FROM STRIKING HER CAR IN THE REAR. IN ORDER TO GET THE VEHICLE HOME (APPROXIMATELY 3 MILES), I HAD TO USE THE EMERGENCY BRAKE TO STOP. COULD NOT AFFORD TO GET THE TRUCK TO THE DEALERSHIP (APPROXIMATELY 15 MILES AWAY IN HEAVY SUBURBAN TRAFFIC) FOR DIAGNOSIS AND REPAIR. SAVED UP AND TOOK THE TRUCK TO A LOCAL MECHANIC (09/2012). MECHANIC ASK IF THE TRUCK HAD EVER BEEN UNDER WATER. REASON FOR QUESTION WAS THE BRAKE LINES, FRONT CALIPERS, AND TOP FORWARD FRAME WERE SEVERELY RUSTED. THE BRAKE LINES RUSTED THROUGH CAUSING A BREAK FAILURE. THIS TRUCK HAS LESS THAN 21,000 MILES, NEVER BEEN SUBMERGED IN WATER, OCCASIONALLY DRIVEN IN THE WINTER, WASHED FREQUENTLY (ESPECIALLY IN THE WINTER) AND WAXED, AND HAS ZERO BODY OR BED RUST. AFTER REPAIR, THE ABS LIGHT CAME ON AND STAYS ON. I READ SOMEWHERE ON THIS SITE A BULLETIN REGARDING PREMATURE ABS SENSOR FAILURE AND DEALERS FIXING THE SENSORS BUT I CAN NOT FIND THE ABS BULLETIN NOW. *TR

2004 CHEVROLET SILVERADO 3500. ATTORNEY WRITES ON BEHALF OF CLIENTS IN REGARDS TO NEGLIGENT DRIVER COLLISION *TGW THE ATTORNEY STATED THE DRIVER OF A TRACTOR TRAILER, DROVE OFF THE EMERGENCY LANE INTO HIS CLIENTS LANE OF TRAVEL RESULTING IN A VERY SEVERE COLLISION, BECAUSE HIS CLIENT WAS UNABLE TO AVOID RUNNING INTO THE REAR OF HIS TRACTOR TRAILER. THE ATTORNEY BELIEVED THE DRIVER WAS TALKING ON HIS CELL PHONE AND WAS IMPROPERLY LOCATED IN THE EMERGENCY LANE AND DID NOT SIGNAL THAT HE WAS ABOUT TO ENTER BACK INTO THE LANE OF TRAVEL. AS A DIRECT AND PROXIMATE RESULT, HIS CLIENTS SUFFERED SIGNIFICANT INJURIES. *JB

IN JANUARY 2004, I BOUGHT A NEW CHEVY 3500 DURAMAX DIESEL TRUCK. SINCE MARCH 2005, I HAVE HAD TO HAVE THE INJECTORS REPLACED A TOTAL OF 6 TIMES. NOW AT 202,000 THE INJECTORS NEED REPLACED AGAIN. CHEVY WILL NOT HELP OUT ON THIS PROBLEM. I HAVE READ THAT EVERYONE SHOULD FILE A COMPLAINT WITH THIS DEPARTMENT SO THAT THIS CAN BE INVESTIGATED. IN NOVEMBER 2011, SOMEONE WAS TOLD THERE WERE NOT COMPLAINTS. BEING A CHEVY OWNER WITH THESE INJECTOR PROBLEMS, I AM WRITING TO COMPLAIN. HOPEFULLY, THIS DEPARTMENT WILL CONDUCT THE INVESTIGATION AND HELP ALL THE OTHER PEOPLE WITH THIS PROBLEM GET A RESPONSE FROM CHEVY TO DO SOMETHING. THESE TRUCKS ARE NOT CHEAP AND JUST BECAUSE WE USE OUR TRUCKS AND PUT MILES ON THEM, AND THEY HAVE REPEATED FAILURES, WE SHOULD NOT HAVE TO BEAR THE BURDEN. THIS PROBLEM WITH MY TRUCK IS IN THE DESIGN. HOW MANY PEOPLE REPLACE INJECTORS EVERY 30-40K MILES? THIS IS WHAT I HAVE HAD TO DO OVER THE LAST 7 YEARS. *TR

BRAKE LINE RUSTED AND FAILED WHILE DRIVING. HEAVY RUST ON SEVERAL BRAKE LINES, FRAME, AND CROSS MEMBERS. *TR

CHEVY SILVERADO 3500 DURAMAX DIESEL, HAS A CRACKED FUEL FILTER HOUSING, CONTACTED CHEVY/GM CUSTOMER CARE REGARDING THIS PROBLEM AND EVEN GAVE THEM A TSB THAT I FOUND ON WEBSITE AND INFORMED THEM OF MANY COMPLAINTS FROM OTHER OWNERS. THEY REFUSE TO REPAIR THE FUEL FILTER HOUSING AT THEIR, WHEN I TOOK VEHICLE IN TO BE CHECKED OUT IT STATES THAT THIS NEEDS TO BE REPAIRED AND COULD BE A SAFETY HAZARD AS FUEL CAN LEAK INTO HOUSING AND CATCH FIRE. I TOLD THE CUSTOMER CARE AGENT OF MY CONCERN ABOUT THE SAFETY OF THIS ISSUE AND WAS TOLD THAT GM/CHEVY WOULD NOT PAY FOR IT! I HAVE HAD MAJOR ISSUES WITH THIS VEHICLE FOR OVER SIX MONTHS AND GM REFUSES TO ASSIST ME WITH MOST OF MY CONCERNS. *TR

BRAKE LINES RUSTED THROUGH CASING BRAKE FAILURE AND A CRASH. NO WARNING LIGHT. *TR

SLOWING DOWN TO TURN INTO A SHOPPING CENTER WHEN THE BRAKE PEDAL WENT TO THE FLOOR. I WAS NOT YET COMMITTED TO THE TURN LANE SO I WAS ABLE TO PASS THE ENTRANCE AND STOP ON THE SIDE OF THE ROAD .THIS IS THE SECOND FAILURE THE FIRST ONE OCCURRED LESS THAN 1000 MILES BEFORE ON 5/23/11 ODI #10402905 .THE SERVICE TECH SAYS THE LINE DON'T LOOK THAT BAD ,AND HE COULD NOT BUY REPLACEMENT LINES FROM CHEVROLET. I HAVE BEEN LUCKY TWICE! *KB

TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 3500. THE CONTACT STATED THAT THE VEHICLE WAS STOPPED WITH THE BRAKES ENGAGED WHEN SHE NOTICED BLACK AND WHITE SMOKE COMING FROM THE MUFFLER. THE FAILURE CONTINUED WHENEVER THE VEHICLE WAS OPERATED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE CONTACT WAS INFORMED THAT THREE OF THE EIGHT INJECTORS FAILED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS UNKNOWN AND THE CURRENT MILEAGE WAS 60,000. UPDATED 07/26/11 *BF THE CONSUMER STATED THREE INJECTORS FAILED. UPDATED 07/28/11