2004 GMC Savana 3500

The 2004 GMC Savana 3500 is a full-size van known for its durability and cargo/passenger hauling capabilities. Engine options for this year include the 4.3L V6 (around 200 hp and 260 lb-ft of torque), the 5.3L V8 (around 295 hp and 335 lb-ft of torque), and the 6.0L V8 (around 300 hp and 360 lb-ft of torque). Transmission options are primarily the 4L60E four-speed automatic. Owners appreciate the Savana’s reliability, cargo space, and towing capacity. Common complaints include fuel economy, ride comfort, and some reliability issues related to the age of the vehicle.

Engine

4.3L V6

• Intake Manifold Gasket Leaks
  • Description/Symptoms: Coolant leaks externally from the front or rear of the intake manifold, leading to overheating and coolant loss.
  • Solution: Replace the intake manifold gaskets.
  • Estimated Cost to Fix: $300 - $500
  • Recalls: None Found

5.3L V8

• Oil Consumption
  • Description/Symptoms: Excessive oil consumption, sometimes exceeding 1 quart per 1,000 miles. Often accompanied by blue exhaust smoke.
  • Solution: Could be PCV valve replacement, or more seriously, piston ring replacement or valve guide repair.
  • Estimated Cost to Fix: $50 - $3,000+ (depending on the root cause)
  • Recalls: None Found
• Knock Sensor Failure
  • Description/Symptoms: Engine misfires, reduced performance, and a check engine light with knock sensor codes (P0325, P0330).
  • Solution: Replace the faulty knock sensor(s) and inspect the wiring harness.
  • Estimated Cost to Fix: $200 - $400
  • Recalls: None Found

6.0L V8

• Exhaust Manifold Bolts Breaking
  • Description/Symptoms: Ticking noise, especially on cold start-up. Exhaust leak detected near the exhaust manifold.
  • Solution: Replace broken exhaust manifold bolts. Can require manifold replacement if bolts are seized or broken off flush with the head.
  • Estimated Cost to Fix: $200 - $800+
  • Recalls: None Found

Transmission

4L60E Four-Speed Automatic

• Harsh Shifting/Slipping
  • Description/Symptoms: Delayed or harsh shifts between gears, particularly 1-2 and 2-3. Transmission slipping under load.
  • Solution: Could be caused by worn valve body, failing solenoids, or worn clutches. Diagnosis is key. May require valve body repair/replacement or complete transmission rebuild.
  • Estimated Cost to Fix: $300 - $3,000+
  • Recalls: None Found
• Torque Converter Failure
  • Description/Symptoms: Shuddering at highway speeds, especially under light acceleration. Possible stalling at stops.
  • Solution: Replace the torque converter. Inspect the transmission fluid for debris, as torque converter failure can contaminate the transmission.
  • Estimated Cost to Fix: $500 - $1,000
  • Recalls: None Found

Suspension

• Worn Ball Joints
  • Description/Symptoms: Clunking noises from the front suspension, especially when going over bumps. Loose steering.
  • Solution: Replace worn ball joints (upper and/or lower).
  • Estimated Cost to Fix: $200 - $600 per side
  • Recalls: None Found
• Leaf Spring Sagging
  • Description/Symptoms: Rear of the van sits lower than normal, especially when loaded. Reduced ride comfort and handling.
  • Solution: Replace or add-a-leaf to the leaf spring packs.
  • Estimated Cost to Fix: $300 - $800
  • Recalls: None Found

Electrical

• Fuel Pump Failure
  • Description/Symptoms: Engine stalling, difficulty starting, and/or a lack of power.
  • Solution: Replace the fuel pump.
  • Estimated Cost to Fix: $400 - $800
  • Recalls: None Found
• ABS Sensor Failure
  • Description/Symptoms: ABS light illuminated on the dashboard. ABS system may not function correctly during braking.
  • Solution: Replace the faulty ABS sensor.
  • Estimated Cost to Fix: $150 - $300
  • Recalls: None Found

Exterior

• Rust on Rocker Panels and Wheel Arches
  • Description/Symptoms: Rust developing on the lower body panels, especially around the rocker panels and wheel arches.
  • Solution: Rust repair or panel replacement.
  • Estimated Cost to Fix: $500 - $2,000+ (depending on severity)
  • Recalls: None Found

Interior

• Headliner Sagging
  • Description/Symptoms: Headliner fabric detaching from the backing board and sagging down.
  • Solution: Replace or re-glue the headliner.
  • Estimated Cost to Fix: $200 - $500
  • Recalls: None Found

Summary

The 2004 GMC Savana 3500, while generally reliable, can suffer from issues common to vehicles of its age. Engine problems like oil consumption, intake manifold leaks, and exhaust manifold bolt failures are not uncommon, especially on higher mileage vehicles. Transmission issues such as harsh shifting and torque converter problems can also occur. Suspension wear and electrical component failures can also affect the van’s reliability. Repair costs range from a few hundred dollars for minor issues to several thousand for major engine or transmission repairs. Body rust can be a significant concern in certain climates. Prospective buyers should thoroughly inspect the vehicle for these potential issues before making a purchase.