2004 GMC Sierra 2500 Service and Repair Manual

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Covers all 2004 Sierra 2500 trims — Base Standard Cab Pickup 2-Door, SLT Crew Cab Pickup 4-Door, Base Extended Cab Pickup 4-Door +6 more ·
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2004 GMC Sierra 2500 service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • Base Standard Cab Pickup 2-Door
  • SLT Crew Cab Pickup 4-Door
  • Base Extended Cab Pickup 4-Door
  • WT Extended Cab Pickup 4-Door
  • SLE Crew Cab Pickup 4-Door
  • SLT Extended Cab Pickup 4-Door
  • SLE Extended Cab Pickup 4-Door
  • WT Standard Cab Pickup 2-Door
  • SLE Standard Cab Pickup 2-Door

Engines covered

  • 6.0L 5967CC 364Cu. In. V8 GAS OHV Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams
NHTSA #04V56200026/11/2004Component: EQUIPMENT ADAPTIVE/MOBILITY

ON CERTAIN VANS EQUIPPED WITH SURE-LOK WHEELCHAIR SECUREMENT SYSTEMS, THE SPROCKET TEETH OF THE RETRACTOR ASSEMBLY IS OUT OF ALIGNMENT.

Consequence

IN THE EVENT OF A VEHICLE CRASH, THE WHEELCHAIR MAY NOT BE ADEQUATELY SECURED POSSIBLY RESULTING IN

Remedy

DEALERS WILL INSPECT AND REPLACE THE WHEELCHAIR SECUREMENT RETRACTORS AS NECESSARY. SURE-LOK WILL H

NHTSA #06E01000001/02/2006Component: STEERING

CERTAIN FABTECH AFTERMARKET REPLACEMENT PITMAN ARMS, P/NOS. FTS71000 AND FTS71001, INSTALLED FOR USE ON CERTAIN 2001-2006 GM C/K 2500 PICK UP TRUCKS AND SPORT UTILITY VEHICLES. THE PIN LOCATED INSIDE

Consequence

LOSS OF STEERING CONTROL COULD LEAD TO A VEHICLE CRASH WITH POTENTIAL INJURY OR DEATH.

Remedy

FABTECH WILL NOTIFY OWNERS AND REPLACE THE PITMAN AND IDLER ARMS FREE OF CHARGE. THE RECALL IS EXPE

TSB #11020816

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

TSB #11017252

This service bulletin provides information for dealers/technicians on OnStar Module 2G Sunset Information.

TSB #11016674

This Preliminary information communicates an issues with the odometer being incorrect after a programming event and how the dealership can resolve the issue.

TSB #11012907

This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.

TSB #11010544

This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.

TSB #11007208

This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed fo

TSB #11006621

Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected mo

TSB #11006421

GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the deal

Showing the 8 most recent of 132 technical service bulletins on file with NHTSA.

20090511Component: AIR BAGSCrash reportedFire reported2 injured1 fatalities

THE TRUCK WAS IN A CLOSE TO HEAD ON CRASH AND NEITHER AIR BAG DEPLOYED,STEERING WHEEL NOR GLOVE BOX AIR BAGS. THERE WAS A DEATH IN THE OTHER CAR. *TR

20061101Component: AIR BAGSCrash reported2 injured

DT*: THE CONTACT STATED WHILE DRIVING 35 MPH, THE VEHICLE WAS HIT BY ANOTHER VEHICLE ON THE RIGHT FRONT SIDE OVER THE TIRE. THERE WAS NO PRE-BRAKING BEFORE THE IMPACT. THE FRONT DRIVER AND PASSENGE

20150309Component: STEERINGCrash reported

TL* THE CONTACT OWNS A 2004 GMC SIERRA 2500. WHILE DRIVING APPROXIMATELY 15 MPH AND MAKING A LEFT TURN, THE POWER STEERING SUDDENLY MALFUNCTIONED CAUSING THE DRIVER TO LOSE CONTROL OF THE VEHICLE AND

20110330Component: SERVICE BRAKES, HYDRAULICCrash reported

LOST BRAKES WHILE DRIVING 35 MPH WAS ABLE TO STOP AND NOTICED BRAKE FLUID DRIPPING FROM ABOVE GAS TANK JUST FORWARD OF REAR AXLE ON DRIVERS SIDE. NEW BRAKE LINE WAS INSTALLED AT GMC DEALER IN JULY 20

20100609Component: ELECTRICAL SYSTEMFire reported

TL* THE CONTACT OWNS A 2004 GMC SIERRA 2500 HD. WHILE THE CONTACT WAS DRIVING BETWEEN 55-60 MPH, SMOKE EXPELLED FROM THE INSTRUMENT PANEL AND AIR VENTS. THE VEHICLE WAS DRIVEN TO THE SIDE OF THE ROADW

Showing the 5 most serious of 175 complaints filed with NHTSA.

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