The 2004 Chevrolet W3500 has 1 NHTSA recall campaign affecting an estimated 253 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 9 complaints with NHTSA, most often about the electrical system. Last updated July 5, 2026.
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…
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.
Complaints by component
ELECTRICAL SYSTEM
1
ENGINE AND ENGINE COOLING
1
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM
1
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:MANIFOLD/HEADER/MUFFLER/TAIL PIPE
1
FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP
1
FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS
1
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS
1
STRUCTURE
1
SUSPENSION:REAR:SHOCK ABSORBER
1
Total complaints9
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information 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…”
“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…”
“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…”
“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…”
“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…”
“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…”
“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”
“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”
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL,
FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 2004 Chevrolet W3500 as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
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