2004 GMC Sierra 2500 Service and Repair Manual
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
ON CERTAIN VANS EQUIPPED WITH SURE-LOK WHEELCHAIR SECUREMENT SYSTEMS, THE SPROCKET TEETH OF THE RETRACTOR ASSEMBLY IS OUT OF ALIGNMENT.
IN THE EVENT OF A VEHICLE CRASH, THE WHEELCHAIR MAY NOT BE ADEQUATELY SECURED POSSIBLY RESULTING IN
DEALERS WILL INSPECT AND REPLACE THE WHEELCHAIR SECUREMENT RETRACTORS AS NECESSARY. SURE-LOK WILL H
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
LOSS OF STEERING CONTROL COULD LEAD TO A VEHICLE CRASH WITH POTENTIAL INJURY OR DEATH.
FABTECH WILL NOTIFY OWNERS AND REPLACE THE PITMAN AND IDLER ARMS FREE OF CHARGE. THE RECALL IS EXPE
This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.
This service bulletin provides information for dealers/technicians on OnStar Module 2G Sunset Information.
This Preliminary information communicates an issues with the odometer being incorrect after a programming event and how the dealership can resolve the issue.
This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.
This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.
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
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
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.
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
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
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
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
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.
