2004 Chevrolet W3500 Recalls, Complaints & Specs
1 safety recall lists the 2004 Chevrolet W3500, and owners have filed 4 complaints with NHTSA. Check your own VIN below.
1 safety recall for the 2004 Chevrolet W3500
Most recent first. Recall repairs are free at any authorised dealer. Click a recall for the full defect, consequence and remedy text.
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Tank assembly (fuel system)
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…
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…
4 owner complaints filed with NHTSA
Owners of the 2004 Chevrolet W3500 have filed 4 complaints with NHTSA. The average mileage at failure in those reports is 143,633 miles. Complaints peaked in 2004 with 1 filed that year.
Most-reported components
What owners are reporting
“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”
Owner complaint to NHTSA, August 13, 2014 · Engine and engine cooling
“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 pro”
Owner complaint to NHTSA, April 13, 2011 · Engine and engine cooling
Compare Chevrolet W3500 model years
Recall and complaint counts for every Chevrolet W3500 model year in NHTSA's database.
| Model year | Recalls | Complaints |
|---|---|---|
| 1998 Chevrolet W3500 | 1 | 1 |
| 2001 Chevrolet W3500 | 0 | 2 |
| 2003 Chevrolet W3500 | 1 | 4 |
| 2004 Chevrolet W3500 | 1 | 4 |
| 2005 Chevrolet W3500 | 0 | 2 |
| 2006 Chevrolet W3500 | 3 | 2 |
| 2007 Chevrolet W3500 | 3 | 2 |
| 2008 Chevrolet W3500 | 3 | 0 |
| 2009 Chevrolet W3500 | 2 | 0 |
Checking a specific 2004 Chevrolet W3500
How do I know if my 2004 Chevrolet W3500 has an open recall?
Enter your 17-character VIN above. The VIN is on the driver's side dashboard (visible through the windshield), the driver's door jamb sticker, and your registration or insurance card. The check runs against NHTSA's live database and tells you which campaigns list your vehicle. 1 campaign currently lists the 2004 Chevrolet W3500; your car may already have been repaired under it.
Is the recall repair free?
Yes. Under federal law, manufacturers must fix safety recalls at no charge for vehicles up to 15 years old from the date of sale to the first owner. Contact any authorised Chevrolet dealer with your VIN and the NHTSA campaign number (for example 05V168000).
What is the difference between a recall and a complaint?
A recall is a safety campaign filed by the manufacturer or ordered by NHTSA, with a defined defect and remedy. A complaint is a report an owner sent to NHTSA; it is not verified, but patterns of complaints are what trigger NHTSA investigations and, eventually, recalls.
Other Chevrolet models
- Malibu19,364 complaints
- Silverado 150018,029 complaints
- Impala10,434 complaints
- Tahoe10,032 complaints
- Equinox9,161 complaints
- Silverado8,799 complaints
- Blazer8,192 complaints
- Suburban8,164 complaints
Source: NHTSA recall and complaint databases and EPA fuel economy data, October 2026. Complaint counts are owner reports to NHTSA, not verified defects. Recall counts are safety campaigns that list this model year; whether a particular car was already repaired depends on its VIN. How this data is compiled.