The 2004 Chevrolet W4500 has 1 NHTSA recall campaign affecting an estimated 253 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 1 complaint with NHTSA, most often about the fuel system, other. 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
FUEL SYSTEM, OTHER:FUEL INJECTION SYSTEM
1
Total complaints1
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information removed.
“On several occasions with the truck there have been significant amounts of smoke bellowing from the exhaust. In some cases, other autos believe the vehicle was on fire. Injectors have been found to be faulty on three occasions requiring replacement at significant costs. Smoke from the exhaust is…”
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 W4500 as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
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