2004 Chevrolet Silverado 2500 Service and Repair Manual

This factory service and repair manual for the 2004 Chevrolet Silverado 2500 covers three cabs — standard, extended and crew — the widest body spread in this run of years, and five trims: Base, WT, LS, LT and 400 SS. Power comes from two naturally aspirated overhead-valve gasoline V8s, the 6.0L of 364 cubic inches and the 5.3L of 325. Because the crew cab changes the rear seating, belt routing and floor wiring, the body sections matter as much as the engine sections on this one.

Engines covered

• 6.0L V8 (364 cu in) — OHV, naturally aspirated, gasoline
• 5.3L V8 (325 cu in) — OHV, naturally aspirated, gasoline

Body styles covered

• 2-door standard cab pickup
• 4-door extended cab pickup
• 4-door crew cab pickup

Trims covered

• Base
• 400 SS
• LS
• LT
• WT

Known issues on the 2004 Silverado 2500. Eight recalls appear for 2004. A parking brake whose friction linings can wear until the brake no longer holds a parked truck is one. A hydraulic brake booster accumulator that can crack and separate from its assembly is another. The third worth spelling out is a fuel rail pulse damper retainer clip that fractures, letting the damper work loose so fuel escapes and can find an ignition source. Of 1,848 complaints, 677 are service brakes, 498 electrical and 140 steering — the hydraulic, wiring and steering diagnostics here cover all three.