2004 Chevrolet W3500 recalls & complaints
Source: NHTSA, updated daily. Last checked 2026-10-18. Recalls apply to specific VINs — run your VIN to confirm.
1 safety recall, most serious first
1. Fuel system
What's wrong, in plain English: Fuel lines, tank or pump. Fuel problems usually mean a leak, and leaks mean fire risk. 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.
What could happen: 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.
The fix: 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.
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 2004 W3500.
- Book a repair at any authorized Chevrolet dealer. Quote NHTSA campaign 05V168000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Manufacturer hotline: 1-800-255-6727.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: FUEL SYSTEM, DIESEL:STORAGE:TANK ASSEMBLY
Summary: 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.
Notes: RECALL NO. 05053. CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.
Useful for owners
- OBD2 code reader — see what the car's computer is reporting
- Compact car fire extinguisher
- 2004 Chevrolet W3500 owner's manual
Owner complaints filed with NHTSA
Most complained-about parts: Engine (2), Body / structure (1), Suspension (1), Brakes (1), Hydraulic (1).
Complaints are unverified reports from owners. A pattern (many complaints about the same part) matters more than any single one.
Read recent complaints (4)
08/13/2014 · Engine
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
04/13/2011 · Engine
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 STATE…
05/24/2007 · Suspension
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…
09/29/2004 · Fuel system
WHILE DRIVING 65 MPH VEHICLE STALLED. VEHICLE WAS TOWED TO THE DEALER FOR INSPECTION, AND MECHANIC DETERMINED THAT FUEL PUMP, COMPUTER SENSOR, AND FUEL LINE NEEDED TO BE REPLACED ,AND REPLACED THEM. HOWEVER, THE PROBLEM RECURRED. *AK