2004 Chevrolet W3500 recalls and problems

The 2004 Chevrolet W3500 has 1 recall and 4 owner complaints on file with NHTSA; the most reported problem area is engine.

How the 2004 compares
Fewest complaintsMost complaints

High complaint count among 6 W3500 model years — 2nd most.

1recalls
4complaints
0crashes
0fires
0injuries
152,000median miles

Owner complaints filed with NHTSA, not verified and not adjusted for sales. Ranking compares this model's own years only.

Does your car have an open recall?
Recalls apply to specific vehicles. Only a VIN lookup on NHTSA's official site shows whether yours is affected and still unrepaired.
Check your VIN →

1 recall

Fuel System

Apr 20, 2005 · NHTSA campaign 05V168000 · 253 vehicles

Problem: 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.

Original NHTSA wording

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.

Risk: 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.

Original NHTSA wording

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 & notes

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.

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.

Recall text as published by NHTSA and the manufacturer.

What owners complain about

Owner complaints filed with NHTSA; one complaint can name several areas. Not verified by NHTSA.

Complaints by year filed

2004: 1 complaints200412007: 1 complaints20072011: 1 complaints20112014: 1 complaints20141

2004 vs. other Chevrolet W3500 years

Owner complaints by model year; the darker bar is the 2004. Click a bar to switch year.

Questions

Does the 2004 Chevrolet W3500 have recalls?

Yes — NHTSA lists 1 recall campaign covering the 2004 Chevrolet W3500, the latest from Apr 20, 2005 (fuel system). A recall applies to specific vehicles: enter your VIN at nhtsa.gov/recalls to see whether yours is affected and still open.

What are the most common problems with the 2004 Chevrolet W3500?

Owner complaints filed with NHTSA most often mention engine (2), electrical system (1), fuel system (1). Complaints are consumer reports and are not verified by NHTSA.