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2004 Chevrolet Tahoe Problems

RepairPal has identified the most common problems with the 2004 Chevrolet Tahoe based on complaints from actual vehicle owners. We'll tell you what the problem is and what it'll take to fix it.

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Known Problems

One or more heater & AC (HVAC) air delivery and/or temperature mode door actuator may fail. This can result in incorrect air delivery or temperature. If this occurs, fault code(s) stored in the HVAC control module should be available to assist with diagnoses.

Illumination of the Check Engine Light can be caused by a loose or worn gas cap.

The front or rear differential may develop an abnormal noise due to worn bearings or another internal fault. Our technicians tell us that a complete overhaul of the affected differential is commonly necessary to correct this condition.

The anti-lock brake system (ABS) front wheel speed sensors are prone to failure. When a sensor fails, the ABS warning light may illuminate and/or the ABS system may activate erratically.

It is common for the fuel level sensor in the fuel tank read the fuel level incorrectly. The sensor must be replaced to correct the condition. Our technicians recommend having the complete fuel pump module replaced on high mileage vehicles.

The 4WD transfer case encoder motor position sensor or the selector switch may fail causing the service 4WD message to be displayed. Fault code(s) stored in the transfer case control module will be of assistance in determining the exact fault causing the message to be displayed.

The power door lock actuators may become slow to operate or stop working completely and require replacement.

The speedometer or other instrument panel gauge may begin to work erratically at times. Our technicians tell us that the instrument cluster must be sent to a repair facility to correct this fault. The warranty has been extended on some of these units to 7 years or 70,000 miles.

The intake manifold gasket may develop and external engine oil or coolant leak. In some cases, an internal coolant leak may occur causing coolant to mix with the engine oil. Our technicians tell us that operating the engine  with a coolant/oil mix can result in internal engine damage. Replacing the intake manifold gasket should correct these leaks.

Our technicians recommend flushing the brake fluid every 60,000 miles.  Brake fluid that is dirty may cause problems in the brake system.

The windshield wipers may not work intermittently due to a faulty wiper motor control board. Our technicians tell us that lightly taping on the wiper motor when the fault occurs should temporarily get the wipers working again. Some vehicles were recalled for this problem and some were not. You will need to check with your local dealer to find out if a specific vehicle was included.

The daytime running lights are prone to burning out. Our technicians tell us that the light sockets may show signs of heat damage but usually are OK. Always be sure to use the correct replacement bulb for the best life expectancy. The new bulb recommendation for 2000-2003 models is #4114K (trade number).

The rear window defogger may stop working due to a wire terminal broken off of the rear glass. Our technicians tell us that terminal can be reattached using a special glue or silver solder.

The anti-lock brake system (ABS) pump may stay running after the ignition is turned off causing the battery to go dead. Our technicians tell us that the ABS control module should be replaced to correct this fault.