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2004 Chevrolet Suburban Recalls & Complaints

6

open safety recalls on record

Critical

265 owner complaints filed · Severity Index 0.38 · updated 2026-08-07

The recalls

Critical06E043000

Fuel System, Gasoline

THIS CONDITION MAY CAUSE AN INADEQUATE SEAL AT THE CONNECTION, POTENTIALLY LEADING TO A FUEL LEAK.

Remedy & full details

HONEYWELL WILL NOTIFY OWNERS AND REPLACE THE FUEL FILTERS FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 18, 2006. OWNERS MAY CONTACT FRAM CUSTOMER SERVICE AT 1-800-890-2075 (OPTION 1).

CERTAIN REPLACEMENT FUEL FILTERS, FRAM BRAND NAME P/N G3727, WITH DATE CODES X52911 THROUGH X60801 SEQUENTIALLY OR X600141 AND A MEXICO COUNTRY OR ORIGIN MARKING ON THE FUEL FILTER HOUSING MANUFACTURED FROM OCTOBER 18, 2005, THROUGH MARCH 21, 2006, SOLD FOR USE ON THE VEHICLES LISTED ABOVE AND ON CERTAIN SCHOOL BUSES. (TO SEE THE SCHOOL BUS ENGINE SIZES, CLICK ON "DOCUMENT SEARCH" AND THEN "BUS APPLICATIONS"). THE CONNECTOR ON THE FUEL FILTER WAS NOT MANUFACTURED TO HONEYWELL'S SPECIFICATION. AS A RESULT, THE O-RING MAY NOT SEAT CORRECTLY ON THE FUEL LINE.

Critical06V289000

Engine And Engine Cooling

IF THE DAMPER COMES LOOSE, A FUEL LEAK MAY RESULT.

Remedy & full details

DEALERS WILL REPLACE THE ENGINE FUEL RAIL PULSE DAMPER RETAINER CLIP FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 31, 2006. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438 AND GMC TRUCKS AT 1-866-996-9463.

ON CERTAIN TRUCKS EQUIPPED WITH AN 8.1L V8 (RPO L8-VIN G) ENGINE HAVE A CONDITION IN WHICH THE ENGINE FUEL RAIL PULSE DAMPER RETAINER CLIP MAY FRACTURE RESULTING IN INADEQUATE RETENTION OF THE DAMPER.

Serious05V163000

Seat Belts:Rear/Other

LAP PORTION OF THE SEAT BELT ROUTING THAT IS NOT LOW AND SNUG ON THE HIPS CAN ALLOW THE LAP BELT TO RIDE UP ON AN OCCUPANT'S ABDOMEN INSTEAD OF FITTING LOW AROUND THEIR HIPBONES, AND THEREFORE, CAN EXPOSE THEM TO MORE RISK OF ABDOMINAL A…

Remedy & full details

DEALERS WILL CUT OPEN THE GUIDE LOOP, REMOVE A PORTION OF THE LOOP, AND THEN THE REMAINING TWO SIDES SHOULD BE FOLDED OVER AND SECURED WITH A RETAINER FREE OF CHARGE. THE RECALL BEGAN ON JULY 21, 2005. OWNERS MAY CONTACT CADILLAC AT 1-866-982-2339, CHEVROLET AT 1-800-630-2438, GMC AT 1-866-996-9463, OR HUMMER AT 1-800-732-5493.

ON CERTAIN CREW CAB PICKUP TRUCKS AND SPORT UTILITY VEHICLES, THE 2ND ROW CENTER OCCUPANT SEAT BELT ROUTING MAY MAKE IT DIFFICULT TO POSITION THE LAP PORTION OF THE SAFETY BELT LOW AROUND THE HIPS OF OCCUPANTS, ESPECIALLY SMALLER OCCUPANTS, SEATED IN THIS POSITION. APPROPRIATE USE OF A CHILD SEAT OR BOOSTER SEAT, AS RECOMMENDED FOR SMALL CHILDREN, DOES IMPROVE THE FIT CONDITION FOR THIS USER GROUP. IN ADDITION TO INSTRUCTIONS ON PROPER INFANT AND YOUNG CHILD RESTRAINT (WITH CHILD SEATS OR BOOSTERS), SPECIAL VERBIAGE FOR RESTRAINING OLDER CHILD IS INCLUDED IN THE OWNER'S MANUAL. ALSO, THE SUGGESTED SEAT BELT FIT/ROUTING FOR ADULTS, IRRESPECTIVE OF SEATING POSITION, IS DESCRIBED IN THE OWNER'S MANUAL TEXT.

Serious06E026000

Exterior Lighting

WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.

Remedy & full details

PRO-A MOTORS WILL NOTIFY OWNERS AND OFFER TO REPURCHASE THE LAMPS. THE RECALL BEGAN ON APRIL 3, 2006. OWNERS MAY CONTACT PRO-A MOTORS AT 323-838-2988.

CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.

Serious05V043000

Service Brakes, Hydraulic

IF A SEPARATION OCCURRED AND THE HOOD OF THE VEHICLE WERE OPEN, FRAGMENTS FROM THE ACCUMULATOR COULD CAUSE INJURY TO PEOPLE IN THE IMMEDIATE AREA.

Remedy & full details

DEALERS WILL TEST THE HYDRO-BOOST ASSEMBLY FOR FUNCTIONAL OPERATION OF THE TWO-FUNCTION VALVE. IF THE HYDRO-BOOST ASSEMBLY FAILS THE TEST, DEALERS WILL REPLACE THE ASSEMBLY FREE OF CHARGE. THE RECALL BEGAN ON MARCH 23, 2005. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438, GMC TRUCKS AT 1-866-996-9463 AND HUMMER AT 1-800-732-5493.

CERTAIN TRUCKS, SPORT UTILITY VEHICLES, AND VANS EQUIPPED WITH BOSCH HYDRO-BOOST BRAKE ASSEMBLIES, THE HYDRAULIC BRAKE BOOSTER PRESSURE ACCUMULATOR MAY CRACK AND SEPARATE FROM THE HYDRO-BOOST ASSEMBLY DURING NORMAL OPERATING CONDITIONS.

Moderate04V045000

Service Brakes, Hydraulic

CONSEQUENTLY, THE VALVE O-RING SEAL MAY FRACTURE.

Remedy & full details

DEALERS ARE TO REPLACE THE HYDRO-BOOST RELIEF VALVE. THE RECALL BEGAN ON JUNE 18, 2004. OWNERS SHOULD CONTACT CADILLAC AT 1-866-982-2339; CHEVROLET AT 1-800-630-2438; GMC AT 1-866-996-9463; OR HUMMER AT 1-866-486-6376.

CERTAIN SPORT UTILITY VEHICLES, PICKUP TRUCKS, AND PASSENGER VANS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 135, ?PASSENGER CAR BRAKE SYSTEMS.? SOME OF THESE VEHICLES WERE PRODUCED WITH AN OUT-OF-SPECIFICATION BRAKE HYDRO-BOOST HOUSING RELIEF VALVE BORE.

Complaint volume

265 this model-year 6 median, same year

Volume alone is not a fault rate — popular vehicles attract more reports. Read it next to the severity mix below.

What owners reported happened

14Crashes
7Fires
13Injuries
0Deaths

Across 265 complaints. Severity Index 0.38.

Severity Index weights each complaint's reported outcome (death ×10, injury ×4, fire ×3, crash ×2) and divides by total complaints. It measures how severe reports are, not how often faults occur.

What owners report most

Electrical System · Inst…41 · 15%Service Brakes32 · 12%Electrical System25 · 9%Vehicle Speed Control11 · 4%Steering10 · 4%Service Brakes, Hydraulic9 · 3%Air Bags8 · 3%Electronic Stability Cont…8 · 3%
  1. Electrical System: Instrument Cluster/Panel — 41 reports
  2. Service Brakes — 32 reports
  3. Electrical System — 25 reports
  4. Vehicle Speed Control — 11 reports
  5. Steering — 10 reports
  6. Service Brakes, Hydraulic — 9 reports
  7. Air Bags — 8 reports
  8. Electronic Stability Control (Esc) — 8 reports
  9. Power Train:Automatic Transmission — 7 reports
  10. Fuel System, Gasoline:Delivery:Fuel Pump — 7 reports

What to do

  1. Find your 17-character VIN on the driver's door jamb or the base of the windscreen.
  2. Check it against NHTSA's official lookup at nhtsa.gov/recalls — the authoritative record for your exact car.
  3. Book the repair with any franchised dealer. Safety recall work is free, with no time limit and regardless of who owns the car now.

Other model years

1995 (7) · 1996 (4) · 1997 (3) · 1998 (3) · 1999 (2) · 2000 (11) · 2001 (8) · 2002 (4) · 2003 (7) · 2004 · 2005 (7) · 2006 (1) · 2007 (4) · 2008 (4) · 2009 (5) · 2010 (3) · 2011 (3) · 2012 (4) · 2013 (4) · 2014 (3) · 2015 (11) · 2016 (6) · 2017 (5) · 2018 (4) · 2019 (3) · 2020 (4) · 2021 (12) · 2022 (4) · 2023 (3) · 2024 (1)

Numbers in brackets are open recall campaigns for that year.

Questions

Does an open recall mean the car is unsafe to drive?

Not usually. NHTSA issues a "do not drive" or "park outside" advisory when a defect is dangerous enough to keep you out of the car — those are flagged Critical above. Everything else should be repaired promptly but is not an immediate stop-driving order.

Do I pay for recall repairs?

No. Federal law requires the manufacturer to fix a safety recall free of charge, including parts and labour, whether or not you are the original owner.

Why are there complaints but no recalls?

Complaints are unverified reports filed by owners. They can prompt an investigation, but many never become recalls — either the fault isn't safety-related or it isn't widespread.