2004 Chevrolet Kodiak problems

General information about Chevrolet-Kodiak
Overview of popular issues
Analysis of common problems
Сomplaints list
Recalls list

The Chevrolet Kodiak and GMC TopKick are a range of medium-duty trucks that were produced by the Chevrolet and GMC divisions of General Motors from 1980 to 2009. Introduced as a variant of the medium-duty C/K truck line, three generations were produced. Slotted between the C/K trucks and the GMC Brigadier Class 8 conventional, the Kodiak/TopKick were developed as a basis for vocationally oriented trucks, including cargo haulers, dump trucks, and similar vehicles; on later generations, both cutaway and cowled-chassis variants were produced for bus use.

Following years of declining market share, General Motors (in line with Ford Motor Company) sought to exit heavy-truck manufacturing. After struggling to enter joint ventures or sell the rights to its product line, the company ended production of the Kodiak and TopKick in 2009. The final medium-duty truck, a GMC TopKick 5500, rolled out of Flint Truck Assembly on July 31, 2009.

For the 2019 model year, after a ten-year hiatus, General Motors re-entered the conventional medium-duty truck segment. Developed in a joint venture with Navistar International, the Chevrolet Silverado 4500/5500 is a Class 4–6 vehicle. Slightly smaller than the Kodiak/Topkick, the Silverado 4500/5500 is marketed exclusively as a Chevrolet (with no GMC counterpart).

Social links

Common 2004 Chevrolet Kodiak problems

Based on complaints from owners of the Chevrolet Kodiak 2004, here are some common problems with this vehicle:

Fuel Injection System Problems: If equipped with the Duramax LB7 engine, which was used in the 2001 – 2004 Chevrolet Kodiak, GMC Topkick, and other models, owners may experience issues with the fuel injection system. Previous owners failing to replace injectors under warranty can lead to inevitable problems with the fuel injection system, causing potential issues with engine performance.

Overheating and Head Gasket Failures: The Duramax LLY engine, found in the 2004 – 2005 Chevrolet Silverado and GMC Sierra HD, is known for overheating issues, especially when towing, and blown head gaskets. These problems can affect the engine's performance and reliability, requiring attention to prevent further damage.

Valvetrain and Engine Noise: Problems with the valvetrain, such as excessive clearance between components or faulty hydraulic valve lifters, can lead to knocking, ticking, or tapping noises in the engine. These noises can indicate issues with the valvetrain components, affecting engine performance and potentially causing further damage if not addressed promptly.

Incorrect Fuel Combustion: Using the wrong type of fuel, especially in engines that require premium fuel, can lead to engine knock or pinging sounds. This issue arises when gas combusts from high compression before the spark ignites it, causing knocking noises. Ensuring the correct fuel type is used is crucial to prevent this problem and maintain engine performance.

These common problems with the Chevrolet Kodiak 2004 can impact the vehicle's reliability, performance, and overall driving experience. Addressing these issues promptly through proper maintenance and repairs is essential to ensure the longevity and optimal functioning of the vehicle.

Why did Chevy stop making the Kodiak?

What engine is in the Kodiak?

ENGINE

Engine Type	686cc liquid-cooled SOHC 4-stroke
Fuel Delivery	Yamaha Fuel Injection (YFI), 44mm
Transmission	Ultramatic V-belt with all-wheel engine braking; H, L, N, R, P
Final Drive	Lever-operated 2WD/4WD; shaft
Fuel Capacity	4.8 gal

What replaced the Chevy Kodiak?

The next-generation Chevrolet Medium Duty Trucks will reach the market for the 2019 model year as two all-new models. The vehicles will not be called Kodiak, however. Instead, they will be named Silverado 4500 and Silverado 5500.

What is the fuel mileage for a 2005 Chevy Kodiak?

Based on data from 6 vehicles, 297 fuel-ups and 83,372 miles of driving, the 2005 Chevrolet C5500 Kodiak gets a combined Avg MPG of 8.17 with a 0.20 MPG margin of error.

Why did Chevy stop making the Kodiak?

What engine is in the Kodiak?

ENGINE

Engine Type	686cc liquid-cooled SOHC 4-stroke
Fuel Delivery	Yamaha Fuel Injection (YFI), 44mm
Transmission	Ultramatic V-belt with all-wheel engine braking; H, L, N, R, P
Final Drive	Lever-operated 2WD/4WD; shaft
Fuel Capacity	4.8 gal

What replaced the Chevy Kodiak?

Is the Kodiak 4 wheel drive?

The Kodiak 700 EPS models are fitted with an easy to operate On-Command® system with 2WD/4WD and 4WD with Diff Lock for full control for quick and effective switching between 2WD and 4WD, or even full Diff Lock allowing you to choose the right option to suit the terrain and surface conditions.

2004 Chevrolet Kodiak car problems categorized by type of issue

After analyzing all complaints sent to the NHTSA and researching popular Chevrolet Kodiak problems, we found that the most common problems with these 2023 model year vehicles are:

Power train problems
Steering problems
Service brakes problems
Hydraulic problems
Suspension problems

The graph below shows statistics for all 2004 Chevrolet Kodiak vehicle components and the number of complaints received.

2004 Chevrolet Kodiak complaints

The NHTSA has received 5 complaints about various vehicle components related to the 2004 Chevrolet Kodiak.

2006-06-19

POWER TRAIN PROBLEM

Date Of Incident: 2006-06-12
VIN: 1GBE5E1264F
Components: POWER TRAIN
Summary: DT*: THE CONTACT STATED THERE WERE NUMEROUS PROBLEMS WITH THE VEHICLE. AT 20,000 MILES, THE LEFT WHEEL BEARING BACKED OUT AND AT 87,000 MILES, THE DRAG LINK FAILED. WHILE DRIVING 80 MPH, THE VEHICLE SUDDENLY DOWN SHIFTED TO 20 MPH WITH NO EFFORT FROM THE CONTACT. WHILE STARTING THE VEHICLE, THE RPM WILL NOT GO BEYOND 2000. THE VEHICLE HAS BEEN TAKEN TO THE DEALER ON NUMEROUS OCCASIONS AND THEY CAN NOT DETERMINE THE PROBLEM. THIS OCCURRED REGARDLESS OF THE TRAFFIC CONDITIONS, SPEED OR TERRAIN.*AK

Add Complaint

2006-05-18

STEERING,SERVICE BRAKES, HYDRAULIC PROBLEM

Date Of Incident: 2006-05-11
VIN: 1GBE5V1134F
Components: STEERING,SERVICE BRAKES, HYDRAULIC
Summary: BRAKE WARNING LIGHT FOR SERVICE BRAKES CAME ON. SOFT BRAKE PEDAL. FURTHER INVESTIGATION REVEALED LOSS OF BRAKE FLUID AND BRAKE FLUID SPRAYED ALL OVER LEFT FRONT WHEEL, CHASSIS, AND FRAME. OUTSIDE BRAKE LINE FROM THE BRAKE PRESSURE MODULATOR HAD A HOLE LEAKING BRAKE FLUID. CAUSE OF WORN BRAKE LINE WAS FROM THE POWER STEERING HOSE COMING FROM THE HYDRAULIC PUMP TO THE INLET SIDE OF THE STEERING GEAR BOX. THE POWER STEERING HOSE WAS RUBBING AGAINST THE BRAKE LINE. POWER STEERING HOSE WAS REPLACED AND BRAKE LINE REPAIRED. DEFECTIVE BRAKE LINE IS AVAILABLE FOR INSPECTION. *JB

Add Complaint

2006-02-17

SUSPENSION,TIRES PROBLEM

Date Of Incident: 2006-02-17
VIN: 1GBE4E1254F
Components: SUSPENSION,TIRES
Summary: DT*: THE CONTACT STATED THE FRONT END OF THE VEHICLE SHOOK AT ANY SPEED. THIS CAUSED ABNORMAL WEAR TO THE FRONT TIRES, THE TIRES MUST BE REPLACED EVERY 10,000 MILES. THE DEALERSHIP WAS UNABLE TO DETERMINE A PROBLEM WITH THE VEHICLE, BUT DETERMINED THE TIRES ARE NOT RATED TO CARRY THE LOAD OF THE VEHICLE.

Add Complaint

2005-10-20

ENGINE AND ENGINE COOLING PROBLEM

Date Of Incident: 2004-07-30
Number Of Injuries: 1
Crash: 1
VIN: 1GBE4E12X4F
Components: ENGINE AND ENGINE COOLING
Summary: DT: THE CONTACT EXPERIENCE A PROBLEM WITH THE DIESEL ENGINE DYING WHILE THE VEHICLE WAS DRIVE. THE VEHICLE DID NOT STALL, BUT SIMPLY DIED AT ONCE WITHOUT WARNING. THE CHECK ENGINE LIGHT ILLUMINATED AS A WARNING, AND THE ENGINE SHUT OFF . THE VEHICLE WAS USED AS A HAULER THAT PULLED A TRAILER DELIVERING BOATS. WHEN THE ENGINE DIED THERE WAS A LOSS OF POWER, RESULTING IN A LOSS OF POWER STEERING AND THE BRAKES. THE ONLY WAY TO STOP THE VEHICLE WAS BY USING THE IN CAB CONTROLLER TO ACTIVATE THE ELECTRIC BRAKES ON THE TRAILER WHICH ULTIMATELY SLOWED AND STOPPED THE VEHICLE. THE VEHICLE HAS BEEN TO 18 DEALERSHIPS ACROSS THE COUNTRY IN AN ATTEMPT TO REPAIR THIS PROBLEM. THE DEALERS WERE CAUSE OF THE UNABLE TO DETERMINE THE PROBLEM. THE VEHICLE DID NOT PRODUCE ANY TYPE OF DIAGNOSTIC CODE. THEREFORE, NO REPAIRS OR CORRECTIONS WERE MADE. THE LATEST INCIDENT RESULTED IN A JACKKNIFE CRASH ON THE HIGHWAY. THERE WAS AN INJURY, AND A POLICE REPORT WAS TAKEN. THE VEHICLE WAS NOT BEING DRIVEN DUE TO THE RISK OF THIS PROBLEM OCCURRING AGAIN. *AK

Add Complaint

2004-10-05

POWER TRAIN PROBLEM

Date Of Incident: 2004-09-27
Components: POWER TRAIN
Summary: CONSUMER IS UNABLE TO KEEP VEHICLE STRAYED OUT OF THE LANE. FRONT END HAD BEEN DONE EIGHT TIMES. THE REAR AXLE WAS MOUNTED WRONGLY ON THE VEHICLE. *AK

Add Complaint

2004 Chevrolet Kodiak recalls

The National Highway Traffic Safety Administration (NHTSA) has issued 5 recalls for different components of the 2004 Chevrolet Kodiak.

2007-10-04

Manufacturer: GENERAL MOTORS CORP.
Components: STEERING
Summary: ON CERTAIN MEDIUM DUTY TRUCKS EQUIPPED WITH ZF MODEL 8018 STEERING GEARS, THE STEERING GEAR MAY HAVE BEEN PRODUCED INCORRECTLY. A STEERING GEAR WITH THIS CONDITION MAY PRODUCE THE FEELING OF HITTING A CURB AND A CRACKING OR PINGING SOUND WHEN THE STEERING WHEEL IS TURNED.
Consequence: THE STEERING WHEEL POSITION MAY BE OFF-CENTER AND INCREASED EFFORT MAY BE REQUIRED WHEN TURNING, INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL INSPECT FOR CERTAIN DATE CODES AND VERIFY THE MILEAGE ON STEERING GEARS AND REPLACE GEARS AS NECESSARY. THE RECALL BEGAN ON OCTOBER 25, 2007. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438; GMC AT 1-866-996-9463; OR ISUZU AT 1-800-255-6727.

2005-06-16

Manufacturer: GENERAL MOTORS CORP.
Components: SERVICE BRAKES, HYDRAULIC:FLUID
Summary: CERTAIN 2003-2005 MODEL YEAR 4500/5500 SERIES CHEVROLET KODIAK, SCHOOL BUS CHASSIS, AND GMC TOPKICK VEHICLES; AND 2003-2004 MODEL YEAR GMC SCHOOL BUS CHASSIS VEHICLES EQUIPPED WITH AN 8.1L ENGINE AND HYDROMAX BRAKE SYSTEM. THE POWER STEERING HOSE MAY COME INTO CONTACT WITH A PORTION OF THE INTERMEDIATE STEERING SHAFT. A HOLE COULD BE WORN IN THE HOSE AND A LOSS OF HYDRAULIC FLUID WOULD OCCUR.
Consequence: IF THERE IS SUFFICIENT AMOUNT OF FLUID LOSS, THE DRIVER WILL HEAR A NOISE FROM THE POWER STEERING PUMP, THE BRAKE WARNING LIGHT AND WARNING TONE WILL ACTIVATE. INCREASED EFFORT MAY BE REQUIRED FOR STEERING AND BRAKING, INCREASING THE RISK OF A CRASH.
Remedy: GM WILL NOTIFY ITS CUSTOMERS AND DEALERS WILL REROUTE THE POWER STEERING HOSE. IF THE STEEL BRAIDING OF THE HOSE IS EXPOSED, DEALERS ARE TO REPLACE THE HOSE FREE OF CHARGE. THE RECALL BEGAN ON JULY 12, 2005. OWNERS MAY CONTACT CHEVROLET AT 800-630-2438 OR GMC AT 866-996-9463.

2005-02-08

Manufacturer: GENERAL MOTORS CORP.
Components: SERVICE BRAKES, HYDRAULIC
Summary: 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.
Consequence: 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. THE PRESENCE OF THIS CRACK OR FRACTURED SURFACE COULD ALLOW THE HYDRAULIC FLUID TO LEAK FROM THE ACCUMULATOR CIRCUIT OF THE BOOSTER ASSEMBLY. THE LOSS OF FLUID WOULD CAUSE INCREASED STEERING AND BRAKING EFFORT AND A CRASH MAY OCCUR WITHOUT PRIOR WARNING.
Remedy: 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.

2004-03-17

Manufacturer: GENERAL MOTORS CORP.
Components: STRUCTURE:BODY:TAILGATE:HINGE AND ATTACHMENTS
Summary: ON CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES, THE GALVANIZED STEEL TAILGATE SUPPORT CABLES THAT RETAIN THE TAILGATE IN THE FULL OPEN (HORIZONTAL) POSITION MAY CORRODE, WEAKEN, AND EVENTUALLY FRACTURE. IF BOTH CABLES FRACTURED, THE TAILGATE WOULD SUDDENLY DROP AND STRIKE THE TOP SURFACE OF THE REAR BUMPER.
Consequence: ANYONE SITTING OR STANDING ON THE HORIZONTAL SURFACE OF THE TAILGATE WHEN BOTH CABLES FRACTURED COULD BE INJURED BY FALLING FROM THE TAILGATE. ON VEHICLES THAT HAVE HAD THE BUMPER REMOVED, THE TAILGATE MAY DROP EVEN LOWER. ADDITIONALLY, IF THERE IS CARGO ON THE TAILGATE THE CARGO MAY FALL OFF IF THE SUPPORT CABLES FRACTURE.
Remedy: DEALERS WILL REPLACE THE CABLES. INTERIM OWNER NOTIFICATION BEGAN ON APRIL 7, 20004. THE RECALL BEGAN ON SEPTEMBER 24, 2004, WHEN REPLACEMENT PARTS WERE AVAILABLE, AND WILL CONTINUE THROUGH OCTOBER 29, 2004. OWNERS SHOULD CONTACT CADILLAC AT 1-866-982-2339, CHEVROLET AT 1-800-630-2438 OR GMC AT 1-866-996-9463, OR VISIT WWW.MYGMLINK.COM, AND ENTER YOUR VEHICLE IDENTIFICATION NUMBER.

2004-03-10

Manufacturer: GENERAL MOTORS CORP.
Components: SERVICE BRAKES, HYDRAULIC:PEDALS AND LINKAGES
Summary: ON CERTAIN TRUCKS, THE SWITCH RETAINER HOLDING THE BRAKE BOOSTER PUSH ROD AND THE BRAKE PEDAL TOGETHER COULD BE MISSING.
Consequence: THIS COULD CAUSE THE PUSH ROD AND PEDAL TO SEPARATE, RESULTING IN A LOSS OF FOUNDATION BRAKES AND INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL INSPECT AND INSTALL A NEW RETAINER IF MISSING. OWNER NOTIFICATION BEGAN MARCH 5, 2004. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT GMCICT AT 1-800-862-4389.

Additional sources

More sources of information about 2004 Chevrolet Kodiak problems:

Common Problems/Issues with c4500/c5500 | Diesel Place

https://www.dieselplace.com/threads/common-problems-issues-with-c4500-c5500.444384/

Jan 15, 2012 ... And theres nothing out there that I would buy to replace it.... ok maybe a Freightliner Sportchassis LOL . 2007 Chevy Kodiak 4500 with 22.5s :D

Chevy C4500 Duramax Q&A: Common Issues & Solutions

https://www.justanswer.com/chevy/9tus8-07-chevy-c4500-duramax-i-m-having-issue.html

Jul 27, 2016 ... 08 Chevrolet C4500 Kodiak With the 6.6 duramax. It won't ... I have a 2009 gmc c5500 duramax with a 6.6 after starting ...

Common Problems/Issues with c4500/c5500 | Page 2 | Diesel Place

https://www.dieselplace.com/threads/common-problems-issues-with-c4500-c5500.444384/page-2

There have been reports of MD trucks needing the Ice Pick Fix. 2004 C5500 Kodiak LLY. Gulf Stream Endura 25,000lbs with car, EGR Blocker & stick. PVC reroute ...

Glow plug issues. Relay? | Chevy and GMC Duramax Diesel Forum

https://www.duramaxforum.com/threads/glow-plug-issues-relay.337586/

Jan 21, 2014 ... ... 2004-chey.html will show you where its at. ... But will start even without it each time. Pete. 2005 Chevy Kodiak c5500 with a 350HP 5.9 cummins ...