2004 Chevrolet W4500 problems

General information about Chevrolet-W4500
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).

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Common 2004 Chevrolet W4500 problems

The Chevrolet W4500, equipped with the 4L80E transmission, has been reported to have several common problems by its owners. Here are some of the most frequently mentioned issues:

Transmission Range Sensor Circuit Range/Performance (P0706): This issue is related to the transmission range sensor circuit, which can cause problems with the shifting of gears. The transmission may have difficulty shifting from one gear to another, or it may not shift at all. This problem can be caused by a faulty transmission range sensor or a wiring issue.
Transmission Fluid Temperature Sensor Circuit Range/Performance (P0711): This issue is related to the transmission fluid temperature sensor circuit, which can cause problems with the shifting of gears. The transmission may have difficulty shifting from one gear to another, or it may not shift at all. This problem can be caused by a faulty transmission fluid temperature sensor or a wiring issue.
Transmission Fluid Temperature Sensor Circuit Low Input (P0712): This issue is related to the transmission fluid temperature sensor circuit, which can cause problems with the shifting of gears. The transmission may have difficulty shifting from one gear to another, or it may not shift at all. This problem can be caused by a faulty transmission fluid temperature sensor or a wiring issue.
Transmission Fluid Temperature Sensor Circuit High Input (P0713): This issue is related to the transmission fluid temperature sensor circuit, which can cause problems with the shifting of gears. The transmission may have difficulty shifting from one gear to another, or it may not shift at all. This problem can be caused by a faulty transmission fluid temperature sensor or a wiring issue.
Torque Converter/Brake Switch B Circuit Low (P0719): This issue is related to the torque converter/brake switch B circuit, which can cause problems with the shifting of gears. The transmission may have difficulty shifting from one gear to another, or it may not shift at all. This problem can be caused by a faulty torque converter/brake switch B or a wiring issue.
Torque Converter/Brake Switch B Circuit High (P0724): This issue is related to the torque converter/brake switch B circuit, which can cause problems with the shifting of gears. The transmission may have difficulty shifting from one gear to another, or it may not shift at all. This problem can be caused by a faulty torque converter/brake switch B or a wiring issue.
Torque Converter Clutch Circuit Malfunction (P0740): This issue is related to the torque converter clutch circuit, which can cause problems with the shifting of gears. The transmission may have difficulty shifting from one gear to another, or it may not shift at all. This problem can be caused by a faulty torque converter clutch or a wiring issue.
Pressure Control Solenoid 'A' Electrical (P0748): This issue is related to the pressure control solenoid 'A' electrical circuit, which can cause problems with the shifting of gears. The transmission may have difficulty shifting from one gear to another, or it may not shift at all. This problem can be caused by a faulty pressure control solenoid 'A' or a wiring issue.
Shift Solenoid 'A' Performance or Stuck Off (P0751): This issue is related to the shift solenoid 'A' performance or being stuck off, which can cause problems with the shifting of gears. The transmission may have difficulty shifting from one gear to another, or it may not shift at all. This problem can be caused by a faulty shift solenoid 'A' or a wiring issue.
Shift Solenoid 'A' Electrical (P0753): This issue is related to the shift solenoid 'A' electrical circuit, which can cause problems with the shifting of gears. The transmission may have difficulty shifting from one gear to another, or it may not shift at all. This problem can be caused by a faulty shift solenoid 'A' or a wiring issue.
Shift Solenoid 'B' Performance or Stuck Off (P0756): This issue is related to the shift solenoid 'B' performance or being stuck off, which can cause problems with the shifting of gears. The transmission may have difficulty shifting from one gear to another, or it may not shift at all. This problem can be caused by a faulty shift solenoid 'B' or a wiring issue.
Shift Solenoid 'B' Stuck On (P0757): This issue is related to the shift solenoid 'B' being stuck on, which can cause problems with the shifting of gears. The transmission may have difficulty shifting from one gear to another, or it may not shift at all. This problem can be caused by a faulty shift solenoid 'B' or a wiring issue.
Shift Solenoid 'B' Electrical (P0758): This issue is related to the shift solenoid 'B' electrical circuit, which can cause problems with the shifting of gears. The transmission may have difficulty shifting from one gear to another, or it may not shift at all. This problem can be caused by a faulty shift solenoid 'B' or a wiring issue.
Shift/Timing Solenoid (P0785): This issue is related to the shift/timing solenoid, which can cause problems with the shifting of gears. The transmission may have difficulty shifting from one gear to another, or it may not shift at all. This problem can be caused by a faulty shift/timing solenoid or a wiring issue.
Transmission Component Slipping (P1860): This issue is related to the transmission component slipping, which can cause problems with the shifting of gears. The transmission may have difficulty shifting from one gear to another, or it may not shift at all. This problem can be caused by a faulty transmission component or a wiring issue.

These problems can be solved by various methods, including buying a used transmission, a rebuilt transmission, or a remanufactured transmission. However, each method has its own advantages and disadvantages, and the best solution depends on the specific situation and the budget of the owner.

2004 Chevrolet W4500 car problems categorized by type of issue

After analyzing all complaints sent to the NHTSA and researching popular Chevrolet W4500 problems, we found that the most common problems with these 2023 model year vehicles are:

Fuel system problems
Other problems

The graph below shows statistics for all 2004 Chevrolet W4500 vehicle components and the number of complaints received.

2004 Chevrolet W4500 complaints

The NHTSA has received 1 complaints about various vehicle components related to the 2004 Chevrolet W4500.

2007-10-11

FUEL SYSTEM, OTHER PROBLEM

Date Of Incident: 2007-09-20
VIN: 1GBE4C1124F
Components: FUEL SYSTEM, OTHER
Summary: ON SEVERAL OCCASIONS WITH THE TRUCK THERE HAVE BEEN SIGNIFICANT AMOUNTS OF SMOKE BELLOWING FROM THE EXHAUST. IN SOME CASES, OTHER AUTOS BELIEVE THE VEHICLE WAS ON FIRE. INJECTORS HAVE BEEN FOUND TO BE FAULTY ON THREE OCCASIONS REQUIRING REPLACEMENT AT SIGNIFICANT COSTS. SMOKE FROM THE EXHAUST IS DUE TO THE FAULTY INJECTORS NOT ALLOWING FUEL INTO THE ENGINE SO AS A RESULT THE ENGINE IS BURNING ONLY OIL AND NO DIESEL FUEL. ENGINE IS EXPOSED TO EXCESSIVE HEAT AND COULD START ON FIRE. *JB

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2004 Chevrolet W4500 recalls

The National Highway Traffic Safety Administration (NHTSA) has issued 1 recalls for different components of the 2004 Chevrolet W4500.

2005-04-20

Manufacturer: ISUZU MANUFACTURING SERVICES OF AMERICA
Components: FUEL SYSTEM, DIESEL:STORAGE:TANK ASSEMBLY
Summary: ON CERTAIN TRUCKS EQUIPPED WITH RPO IK9, DUE TO INSUFFICIENT DURABILITY AND TESTING, THE FUEL SWITCHING MANIFOLD SOLENOIDS LACK WATER OR SALT INTRUSION RESISTANCE, WHICH CAN LEAD TO FAILURE OF ONE OR MORE SOLENOIDS. FUEL SWITCHING MANIFOLD SOLENOID FAILURE WILL CAUSE INCORRECT FUEL DELIVERY RESULTING IN FUEL OVERFLOW FROM THE FUEL FILLER NECK.
Consequence: OVERFLOW FUEL MAY RESULT IN HIGH AMOUNT OF DIESEL FUEL LEAKAGE. FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
Remedy: DEALERS WILL REPLACE THE SOLENOID VALVE ASSEMBLY WITH AN IMPROVED ASSEMBLY INCLUDING ADDITIONAL DETECTION CIRCUIT AND ENHANCED WATER RESISTANCE FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 27, 2005. OWNERS MAY CONTACT ISUZU AT 1-800-255-6727.

Additional sources

More sources of information about 2004 Chevrolet W4500 problems:

GMC W4500 Q&A: Common Problems, Reviews, and Sales ...

https://www.justanswer.com/medium-and-heavy-truck/7a8ab-2006-gmc-w4500-5-2l-diesel-cab-aisin-speed-auto-tranny.html

Oct 30, 2012 ... 2006 GMC w4500 5.2L diesel cabover aisin 4 speed auto tranny. My question is: what would cause reverse to not work?

anyone using a GAS Isuzu NPR, GMC W4500, Chevy W4500 ...

https://mikeysboard.com/threads/anyone-using-a-gas-isuzu-npr-gmc-w4500-chevy-w4500.243839/

same trucks all three, if so, what could one expect as far as reliability, fuel economy with a decent sized box, etc.

Common GMC W4500 Problems: Q&A for 2007 GMC W4500 Cab ...

https://www.justanswer.com/medium-and-heavy-truck/ahwj4-2007-gmc-w4500-cab-start-runs-fine.html

Jun 21, 2017 ... I have a 2007 gmc w4500 cab over it start and runs fine if you put it in gear and do brake stand it ok until wheel turn - Answered by a ...

chevrolet/isuzu 5.2L diesel | Lawn Care Forum

https://www.lawnsite.com/threads/chevrolet-isuzu-5-2l-diesel.206925/

Nov 19, 2007 ... 446 posts · Joined 2004. Add to quote · Only ... 5.2 engine is a good strong engine, one thing ... We ran into some problems. Please try again ...