2004 GMC Sierra 2500 HD Problems
RepairPal has identified the most common problems with the 2004 GMC Sierra 2500 HD based on complaints from actual vehicle owners. We'll tell you what the problem is and what it'll take to fix it.
One or more heater & AC (HVAC) temperature and/or air delivery mode door actuator may fail, resulting in improper temperature or air delivery. If this occurs, fault code(s) should be stored in the HVAC control module which should assist in diagnoses.
The GMC Sierra 2500 HD uses a throttle position sensor (TPS) which commonly fails and causes:
- Check engine light illumination
- Reduced Power message
- OBD trouble code P2135
This issue is related to the throttle position sensor, and can be caused by faulty wiring to the TPS, bad connection at the TPS, or a failed TPS.
To correct this issue, the wiring harness, connector, and throttle position sensor must be inspected, tested, and/or replaced. The most common cause is a faulty TPS.
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 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.
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.
Illumination of the Check Engine Light can be caused by a loose or worn gas cap.
The 2004-2007 GMC Sierra 2500 HD is known to have issues with the EVAP system, a part of your emission control system.
To correct the issue, the EVAP canister vent valve, solenoid, and wiring must be inspected. The most common fix is replacement of the wiring connector or replacement of the vent valve assembly.
The headlight switch used on the GMC Sierra 2500 HD is known to fail through normal operation. Since the headlight switch is also integrated into the interior lights, a malfunctioning switch can cause issues with interior lights as well.
- Symptoms of a failed headlight switch include:
- Headlights and taillights failing to turn on or off
- Interior lights flicker, or fail to turn on or off
- Gauge cluster lighting off or flickering with headlights on
- Parking light malfunctions
This issue is well known with General Motors Trucks and SUVs, and is solved by testing and, if needed, replacing the headlight/dimmer switch. Bad grounding wires at the tail-lights, and dirty/corroded tow package wires can also lead to some of these issues.
The fuel pump may fail causing the engine to stall and not restart.
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 2001-2003 models is #4114K (trade number).
The spark plugs should be replaced every 100,000 miles. Our technicians recommend replacing the spark plug wires also at this time.
The muffler heat shield may become loose on the muffler causing a rattle or popping noise. Our technicians tell us there is a kit available from GM to correct this problem.
A poor electrical ground under the battery tray may cause the ABS warning light to illuminate. Our technicians tell us that cleaning and properly securing this ground and also the main ABS ground on the frame rail below the drivers door may be necessary.