The 2004 Chevrolet Tahoe has 2 NHTSA recall campaigns affecting an estimated 1,428,699 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 548 complaints with NHTSA, most often about the electrical system. Last updated July 5, 2026.
Recall campaigns
SEAT BELTS05V1630002005-04-221,359,824 affected
Defect
ON CERTAIN CREW CAB PICKUP TRUCKS AND SPORT UTILITY VEHICLES, THE 2ND ROW CENTER OCCUPANT SEAT BELT ROUTING MAY MAKE IT DIFFICULT TO POSITION THE LAP PORTION OF THE SAFETY BELT LOW AROUND THE HIPS OF OCCUPANTS, ESPECIALLY SMALLER OCCUPANTS, SEATED IN THIS POSITION. APPROPRIATE USE OF A CHILD SEAT OR BOOSTER SEAT,…
Consequence
A LAP PORTION OF THE SEAT BELT ROUTING THAT IS NOT LOW AND SNUG ON THE HIPS CAN ALLOW THE LAP BELT TO RIDE UP ON AN OCCUPANT'S ABDOMEN INSTEAD OF FITTING LOW AROUND THEIR HIPBONES, AND THEREFORE, CAN EXPOSE THEM TO MORE RISK OF ABDOMINAL AND INTERNAL ORGAN INJURY.
Remedy
DEALERS WILL CUT OPEN THE GUIDE LOOP, REMOVE A PORTION OF THE LOOP, AND THEN THE REMAINING TWO SIDES SHOULD BE FOLDED OVER AND SECURED WITH A RETAINER FREE OF CHARGE. THE RECALL BEGAN ON JULY 21, 2005. OWNERS MAY CONTACT CADILLAC AT 1-866-982-2339, CHEVROLET AT 1-800-630-2438, GMC AT 1-866-996-9463, OR HUMMER AT…
SERVICE BRAKES, HYDRAULIC04V0450002004-02-0468,875 affected
Defect
CERTAIN SPORT UTILITY VEHICLES, PICKUP TRUCKS, AND PASSENGER VANS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 135, ?PASSENGER CAR BRAKE SYSTEMS.? SOME OF THESE VEHICLES WERE PRODUCED WITH AN OUT-OF-SPECIFICATION BRAKE HYDRO-BOOST HOUSING RELIEF VALVE BORE.
Consequence
CONSEQUENTLY, THE VALVE O-RING SEAL MAY FRACTURE. STEERING EFFORTS MAY BE SLIGHTLY INCREASED WHILE BRAKING OR PARKING. UNDER CERTAIN DRIVING CONDITIONS, A FRACTURED SEAL MAY REQUIRE A SLIGHT INCREASE IN THE APPLIED BRAKE PEDAL EFFORT TO ACHIEVE THE SAME VEHICLE DECELERATION RATE AS PRIOR TO THE SEAT FRACTURE.
Remedy
DEALERS ARE TO REPLACE THE HYDRO-BOOST RELIEF VALVE. THE RECALL BEGAN ON JUNE 18, 2004. OWNERS SHOULD CONTACT CADILLAC AT 1-866-982-2339; CHEVROLET AT 1-800-630-2438; GMC AT 1-866-996-9463; OR HUMMER AT 1-866-486-6376.
Complaints by component
ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL
124
ELECTRICAL SYSTEM
84
1crashes2fires
SERVICE BRAKES
59
10crashes1fires3injuries
ENGINE
26
1crashes2fires
VEHICLE SPEED CONTROL
25
1crashes2injuries
STEERING
21
1crashes
SERVICE BRAKES, HYDRAULIC
14
POWER TRAIN
12
AIR BAGS
11
6crashes9injuries
POWER TRAIN:AUTOMATIC TRANSMISSION
10
1crashes1injuries
Total complaints548
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information removed.
“My tahoe has the new process 246gm transfer case. They have a known issue called pump rub where the pump is to close to the magnesium shell, and rubs pin holes in the shell which causes fluid to dissipate over time causing the transfer case to run dry burning it up. I've had a mechanic check it…”
“The contact's spouse owns a 2004 chevrolet tahoe. The contact stated while driving approximately 35 mph, the brake pedal was depressed and remained extended to the floorboard. The contact engaged the parking brake to bring the vehicle to a complete stop. The vehicle was driven to the residence and…”
“The contact owns a 2004 chevrolet tahoe. The contact stated that while driving at an undisclosed speed, the brakes failed to stop the vehicle immediately while the brake pedal was being depressed. The vehicle was taken to the dealer where it was diagnosed that the failure was related to nhtsa…”
“The contact owns a 2004 chevrolet tahoe. The contact stated that while inspecting the coils under the hood, he noticed that the master cylinder brake lines were leaking. The vehicle was taken to an independent mechanic who diagnosed that the master cylinder brake lines needed to be replaced. The…”
“My2004 chevy tahoe lt was moving when the rear view mirror fell off the windshield. Also the exhaust manifold bolts have broken off which cause bad gas mileage and slow take offs.”
“My2004 chevy tahoe lt was moving when the rear view mirror fell off the windshield. Also the exhaust manifold bolts have broken off which cause bad gas mileage and slow take offs.”
“Brakes not working when pressed caused an accident”
“The tahoe used as our volunteer fire department medical truck was spewing fuel from above the gas tank. We dropped the tank and found the lines on the top of the fuel tank rusted severely to the point of failure. It was first noticed on a medical run with the engine idling.”
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL,
FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 2004 Chevrolet Tahoe as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
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