2004 Chevrolet Silverado 3500 Service and Repair Manual

This factory service and repair manual for the 2004 Chevrolet Silverado 3500 covers a truck sold five ways and specified five ways, from a crew cab pickup down to a two-door cab and chassis, and from a work-oriented WT up through Base, HD, LS and LT. Under the hood the choice is between three gasoline V8s — 5.7L, 6.0L in gasoline or CNG form, and the 496-cubic-inch 8.1L — or the turbocharged 6.6L diesel, each with its own fuel, ignition and cooling procedures, torque values and diagnostic routines.

Engines covered

• 6.6L V8 (403 cu in) — OHV, turbocharged, diesel
• 6.0L V8 (364 cu in) — OHV, naturally aspirated, gasoline or CNG
• 8.1L V8 (496 cu in) — OHV, naturally aspirated, gasoline
• 5.7L V8 (350 cu in) — OHV, naturally aspirated, gasoline

Body styles covered

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

Trims covered

• Base
• HD
• LS
• LT
• WT

Known issues on the 2004 Silverado 3500. Eight recalls are on the federal record. On the 8.1L V8 a fuel rail pulse damper retainer clip can fracture and let the damper work loose, leaking fuel near ignition sources. A hydraulic brake booster accumulator can crack and separate from the assembly, throwing fragments. Parking brake linings can wear until the brake no longer holds and the truck rolls away. Others cover a lap belt that rides high on the abdomen and lamps without amber side reflectors. Of 1,848 complaints, 677 fall on the service brakes and 498 on the electrical system.