2004 GMC Sierra 2500

The 2004 GMC Sierra 2500 is a heavy-duty pickup truck known for its towing and hauling capabilities. Engine options include the 6.0L Vortec V8 (300 hp, 360 lb-ft of torque), the 8.1L Vortec V8 (330 hp, 450 lb-ft of torque), and the 6.6L Duramax Diesel V8 (300 hp, 520 lb-ft of torque). Transmission options are typically a 4-speed automatic or a 5-speed manual, depending on the engine. Owners often praise the truck’s reliability, power, and comfortable ride, while common complaints include fuel economy, rust, and some electrical gremlins.

Engine

6.0L Vortec V8

• Intake Manifold Gasket Failure
  • Description/Symptoms: Coolant leak, overheating, white smoke from the exhaust, rough running engine.
  • Solution: Replace the intake manifold gasket.
  • Estimated Cost to Fix: $300 - $700+
  • Recalls: None Found
• Oil Pressure Sensor Failure
  • Description/Symptoms: Erratically fluctuating or completely inoperative oil pressure gauge, check engine light.
  • Solution: Replace the oil pressure sensor.
  • Estimated Cost to Fix: $100 - $300+
  • Recalls: None Found

8.1L Vortec V8

• Exhaust Manifold Bolts Breakage
  • Description/Symptoms: Exhaust leak noise, reduced fuel economy, check engine light.
  • Solution: Replace the exhaust manifold bolts and possibly the manifold itself if warped.
  • Estimated Cost to Fix: $200 - $800+
  • Recalls: None Found
• Oil Consumption
  • Description/Symptoms: Excessive oil consumption between oil changes, blue smoke from the exhaust.
  • Solution: Address underlying cause (valve seals, piston rings, etc.), potentially requiring an engine rebuild.
  • Estimated Cost to Fix: $500 - $5000+
  • Recalls: None Found

6.6L Duramax Diesel V8 (LB7)

• Fuel Injector Failure
  • Description/Symptoms: White smoke from the exhaust, rough running engine, decreased fuel economy, engine knock.
  • Solution: Replace the faulty fuel injectors.
  • Estimated Cost to Fix: $2,000 - $8,000+
  • Recalls: GM Recall #04056 - Some models may have needed fuel injector replacement.
• Glow Plug Failure
  • Description/Symptoms: Hard starting, especially in cold weather, white smoke at startup.
  • Solution: Replace the faulty glow plug(s).
  • Estimated Cost to Fix: $200 - $800+
  • Recalls: None Found

Transmission

4L80E 4-Speed Automatic

• Harsh Shifting/Slipping
  • Description/Symptoms: Hard or delayed shifts, slipping between gears, transmission overheating.
  • Solution: Could be due to low fluid, faulty solenoids, or internal damage requiring a rebuild.
  • Estimated Cost to Fix: $100 (fluid) - $3000+ (rebuild)
  • Recalls: None Found

NV4500 5-Speed Manual

• 5th Gear Failure
  • Description/Symptoms: Inability to engage or stay in 5th gear, grinding noises when shifting into 5th.
  • Solution: Rebuild or replace the transmission, addressing the 5th gear issue.
  • Estimated Cost to Fix: $1500 - $4000+
  • Recalls: None Found

Suspension

• Ball Joint Failure
  • Description/Symptoms: Clunking noise from the front end, uneven tire wear, loose steering.
  • Solution: Replace the worn ball joints.
  • Estimated Cost to Fix: $200 - $600+
  • Recalls: None Found
• Pitman Arm/Idler Arm Wear
  • Description/Symptoms: Loose steering, wandering on the road, difficulty maintaining a straight line.
  • Solution: Replace the worn pitman arm and/or idler arm.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found

Electrical

• Instrument Cluster Issues
  • Description/Symptoms: Gauges not working properly (speedometer, fuel gauge, etc.), flickering or dim display.
  • Solution: Repair or replace the instrument cluster.
  • Estimated Cost to Fix: $150 - $600+
  • Recalls: None Found
• Body Control Module (BCM) Issues
  • Description/Symptoms: Intermittent electrical problems, such as power windows, door locks, or lights not working correctly.
  • Solution: Diagnose the BCM and repair or replace it.
  • Estimated Cost to Fix: $200 - $800+
  • Recalls: None Found

Exterior

• Rust on Rocker Panels and Cab Corners
  • Description/Symptoms: Visible rust formation, especially in areas prone to moisture and road salt exposure.
  • Solution: Repair or replace the affected panels, depending on the severity.
  • Estimated Cost to Fix: $500 - $2000+
  • Recalls: None Found

Interior

• Dashboard Cracking
  • Description/Symptoms: Cracks appearing on the dashboard surface, often due to sun exposure and temperature fluctuations.
  • Solution: Replace the dashboard or use a dashboard cover.
  • Estimated Cost to Fix: $100 (cover) - $1000+ (replacement)
  • Recalls: None Found

Summary

The 2004 GMC Sierra 2500, while a capable and popular truck, has its share of common issues. Engine problems like intake manifold leaks and fuel injector failures (Duramax) can be costly. Transmission issues, especially with the 4L80E and NV4500, are also potential concerns. Suspension components like ball joints and steering linkages are prone to wear. Rust is a significant issue, particularly in regions with harsh winters. Interior issues like dashboard cracking are also common. The severity and cost of repairs vary widely depending on the specific issue, but owners should be prepared for potential maintenance expenses. The Duramax diesel, while powerful, comes with the added expense of diesel-specific repairs.