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2004 Chevrolet W3500Problems, recalls & complaints

NHTSA has logged 4 owner complaints about the 2004 Chevrolet W3500, most often about the engine and engine cooling. It is covered by 1 safety recall.

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CarFlaw IndexNot enough dataHigher is better (0–100)
Safety recalls1Free fix at dealersOwner complaints40 with a crash, fire or injuryTypical failure mileage152kEngine and engine cooling, median miles

Source: NHTSA complaints, recalls, investigations and manufacturer recall reports, through August 13, 2014. Updated daily.

Complaints by system

Where the 2004 Chevrolet W3500 has problems

4 complaints grouped by the system owners reported.

Box size = number of complaints naming that system. Darker = larger share. One complaint can name more than one system.
Complaints by system
SystemComplaintsCrash, fire or injury
Engine and engine cooling20
Electrical system10
Fuel system, gasoline10
Service brakes, hydraulic10
Structure10
Suspension10

Source: NHTSA Office of Defects Investigation. Complaints are submitted by the public and are not verified by NHTSA.

1 recall

2004 Chevrolet W3500 recalls and how many were fixed

Each ring shows the share of affected cars repaired, from the manufacturer’s latest quarterly report to NHTSA. Recall repairs are free at authorized dealers.

Recalls apply to specific cars. To see whether a recall is still open on yours, enter the 17-character VIN at nhtsa.gov/recalls or with Chevrolet.

Best & worst years

2004 vs. every other W3500 year

Bars show complaints per model year. Colors show the CarFlaw verdict: complaints weighted for crashes, fires and injuries, adjusted for years on the road and compared with the W3500 median. How we score

'98'01'03'04'05'06'07'08'09
  • Avoid
  • Caution
  • Solid
  • Best
  • Not rated
In owners' words

What W3500 owners report

Recent engine and engine cooling complaints filed with NHTSA, shortened. Personal details are removed.

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…
Complaint 10622124 · Aug 13, 2014 · 63,000 miles
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…
Complaint 10395710 · Apr 13, 2011 · 152,000 miles

Own a 2004 W3500?

Decode your VIN to see the recalls for your exact car, then confirm open recalls with NHTSA.