2004 GMC Sierra 3500

The 2004 GMC Sierra 3500 is a heavy-duty pickup truck known for its towing and hauling capabilities. Engine options included the 6.0L Vortec V8 (300 hp, 360 lb-ft of torque) and the 6.6L Duramax Turbo Diesel V8 (300 hp, 520 lb-ft of torque). Transmission options were the 4L80E four-speed automatic (with the 6.0L V8) and the Allison 1000 five-speed automatic (exclusively with the Duramax Diesel). Owners appreciate the Sierra 3500 for its robust performance and reliability, particularly for work-related tasks. Some common dislikes include its age-related maintenance needs and fuel economy.

Engine

6.0L Vortec V8

• Oil Consumption
  • Description/Symptoms: Excessive oil consumption, requiring frequent top-offs between oil changes. Blue smoke may be visible from the exhaust.
  • Solution: Replacing valve seals.
  • Estimated Cost to Fix: $500 - $1500+
  • Recalls: None Found
• Intake Manifold Gasket Failure
  • Description/Symptoms: Coolant leak at the front or rear of the engine, near the intake manifold. Overheating may occur.
  • Solution: Replace the intake manifold gasket.
  • Estimated Cost to Fix: $300 - $800
  • Recalls: None Found

6.6L Duramax Turbo Diesel V8 (LB7)

• Injector Failure
  • Description/Symptoms: Rough idling, misfires, excessive black smoke, and reduced fuel economy. This is a well-known issue with the LB7 Duramax engine.
  • Solution: Replacement of the faulty injectors.
  • Estimated Cost to Fix: $3,000 - $8,000 (due to complexity and multiple injectors)
  • Recalls:
    • 04034: Some 2001-2004 vehicles may have been manufactured with fuel injectors that crack and leak fuel. This can cause fuel odor, rough running, and/or hard starting. Dealers will replace the fuel injectors.
    • 04054: Some 2001-2004 vehicles may have been manufactured with fuel injectors that crack and leak fuel. This can cause fuel odor, rough running, and/or hard starting. Dealers will replace the fuel injectors.
• Fuel Filter Housing Leak
  • Description/Symptoms: Diesel fuel leak near the fuel filter housing.
  • Solution: Replacing the fuel filter housing or associated seals/gaskets.
  • Estimated Cost to Fix: $200 - $500
  • Recalls: None Found

Transmission

4L80E Four-Speed Automatic

• Slipping or Erratic Shifting
  • Description/Symptoms: Transmission slips during gear changes, delayed engagement, or erratic shifting patterns.
  • Solution: Rebuild or replace the transmission.
  • Estimated Cost to Fix: $1,500 - $4,000+
  • Recalls: None Found
• Torque Converter Failure
  • Description/Symptoms: Shuddering at low speeds, especially when accelerating. Can also cause overheating of the transmission fluid.
  • Solution: Replace the torque converter.
  • Estimated Cost to Fix: $500 - $1500
  • Recalls: None Found

Allison 1000 Five-Speed Automatic

• Torque Converter Clutch (TCC) Failure
  • Description/Symptoms: Shuddering or vibrations at highway speeds, particularly when the TCC engages.
  • Solution: Replace the torque converter.
  • Estimated Cost to Fix: $800 - $2000
  • Recalls: None Found
• Internal Leakage
  • Description/Symptoms: Loss of transmission fluid, difficulty shifting, and eventual transmission failure if not addressed.
  • Solution: Transmission rebuild or replacement.
  • Estimated Cost to Fix: $2,500 - $5,000+
  • Recalls: None Found

Suspension

• Ball Joint Failure
  • Description/Symptoms: Clunking noises from the front end, excessive tire wear, and loose steering.
  • Solution: Replace the upper and/or lower ball joints.
  • Estimated Cost to Fix: $300 - $1000+ per side
  • Recalls: None Found
• Leaf Spring Sagging/Cracking
  • Description/Symptoms: Rear end sagging, reduced load-carrying capacity, and potential leaf spring breakage.
  • Solution: Replace the leaf springs.
  • Estimated Cost to Fix: $500 - $1500+ per side
  • Recalls: None Found

Electrical

• Instrument Cluster Issues
  • Description/Symptoms: Erratic gauge readings, complete gauge failure, and dim or non-functional backlighting.
  • Solution: Repair or replace the instrument cluster.
  • Estimated Cost to Fix: $300 - $800
  • Recalls: None Found
• Body Control Module (BCM) Problems
  • Description/Symptoms: Intermittent electrical issues such as power windows, door locks, or lights malfunctioning.
  • Solution: Diagnose and replace the BCM.
  • Estimated Cost to Fix: $400 - $1200
  • Recalls: None Found

Exterior

• Rust on Rocker Panels and Cab Corners
  • Description/Symptoms: Rust developing on the lower rocker panels and cab corners.
  • Solution: Cut out the rust and weld in new panels or apply rust repair.
  • Estimated Cost to Fix: $500 - $2000+
  • Recalls: None Found
• Door Handle Breakage
  • Description/Symptoms: Exterior door handles break, especially in cold climates.
  • Solution: Replace the door handles.
  • Estimated Cost to Fix: $50 - $200 per handle
  • Recalls: None Found

Interior

• Dashboard Cracking
  • Description/Symptoms: Cracks appearing on the dashboard, especially in sunny regions.
  • Solution: Replacement of the dashboard cover, or dashboard replacement.
  • Estimated Cost to Fix: $200 - $1000+
  • Recalls: None Found
• Power Seat Malfunctions
  • Description/Symptoms: Power seats fail to move in one or more directions.
  • Solution: Repair or replace the seat motor or switch.
  • Estimated Cost to Fix: $150 - $500
  • Recalls: None Found

Summary

The 2004 GMC Sierra 3500, while a capable and dependable truck, has several age-related problems that potential buyers should be aware of. The Duramax diesel engine is prone to expensive injector failures, while both the gasoline and diesel engines can experience oil leaks. Transmission issues can be costly, particularly with the Allison 1000. Suspension and electrical problems are also common. Overall, while the truck is robust, buyers should factor in the potential for significant repair costs when considering purchasing one.