2004 Chevrolet Avalanche
Safety Recalls & Notices
12 Active Recalls
Requires attention
Heater And Defroster
Summary
On certain vehicles, the interface between the electrical terminals of the Heating, Ventilation, and Air Conditioning (HVAC) blower relay resistor module and the wiring connector (which powers the module) may be incapable of conducting higher current levels for sustained periods of operation. In addition, moisture and other contaminants (such as road de-icing materials) may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. These conditions may cause the relay resistor module or wiring connector to overheat, causing various symptoms such as: the HVAC blower may not function on certain or all blower speed settings; a burning-plastic smell or smoke may be present in the vehicle, or; the HVAC blower may run continually with the ignition in the OFF position. These warning signs could, in certain instances, be leading indicators of an impending vehicle fire, which could result in property damage and/or personal injury. Correction: Owners will be provided with additional warranty coverage for the blower motor resistor module/wiring connector overheating condition. Under this "special warranty coverage", should this condition occur within 10 years or 240,000 km from first vehicle registration, dealers will install a replacement blower motor resistor and resistor module connector.
Fuel System
Summary
On certain vehicles, the engine fuel rail pulse damper retainer clip may fracture, resulting in inadequate retention of the damper. If the damper comes loose, a fuel leak may result. Fuel leakage in the presence of an ignition source could result in a fire. Correction: Dealers will replace the engine fuel rail pulse damper retainer clip.
ENGINE AND ENGINE COOLING
Summary
ON CERTAIN TRUCKS EQUIPPED WITH AN 8.1L V8 (RPO L8-VIN G) ENGINE HAVE A CONDITION IN WHICH THE ENGINE FUEL RAIL PULSE DAMPER RETAINER CLIP MAY FRACTURE RESULTING IN INADEQUATE RETENTION OF THE DAMPER.
Potential Consequence
IF THE DAMPER COMES LOOSE, A FUEL LEAK MAY RESULT. FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
Remedy
DEALERS WILL REPLACE THE ENGINE FUEL RAIL PULSE DAMPER RETAINER CLIP FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 31, 2006. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438 AND GMC TRUCKS AT 1-866-996-9463.
FUEL SYSTEM, GASOLINE
Summary
CERTAIN REPLACEMENT FUEL FILTERS, FRAM BRAND NAME P/N G3727, WITH DATE CODES X52911 THROUGH X60801 SEQUENTIALLY OR X600141 AND A MEXICO COUNTRY OR ORIGIN MARKING ON THE FUEL FILTER HOUSING MANUFACTURED FROM OCTOBER 18, 2005, THROUGH MARCH 21, 2006, SOLD FOR USE ON THE VEHICLES LISTED ABOVE AND ON CERTAIN SCHOOL BUSES. (TO SEE THE SCHOOL BUS ENGINE SIZES, CLICK ON "DOCUMENT SEARCH" AND THEN "BUS APPLICATIONS"). THE CONNECTOR ON THE FUEL FILTER WAS NOT MANUFACTURED TO HONEYWELL'S SPECIFICATION. AS A RESULT, THE O-RING MAY NOT SEAT CORRECTLY ON THE FUEL LINE.
Potential Consequence
THIS CONDITION MAY CAUSE AN INADEQUATE SEAL AT THE CONNECTION, POTENTIALLY LEADING TO A FUEL LEAK. IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.
Remedy
HONEYWELL WILL NOTIFY OWNERS AND REPLACE THE FUEL FILTERS FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 18, 2006. OWNERS MAY CONTACT FRAM CUSTOMER SERVICE AT 1-800-890-2075 (OPTION 1).
Seats And Restraints
Summary
On certain vehicles, the 2nd row centre occupant seat belt routing may make it difficult to position the lap portion of the safety belt low around the hips of occupants. A lap portion of the seat belt routing that is not low and snug on the hips can allow unfavourable occupant kinetics in the event of a crash. Moreover, the higher routing allows 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. Correction: Dealers will modify the guide loop.
SEAT BELTS:REAR/OTHER
Summary
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, AS RECOMMENDED FOR SMALL CHILDREN, DOES IMPROVE THE FIT CONDITION FOR THIS USER GROUP. IN ADDITION TO INSTRUCTIONS ON PROPER INFANT AND YOUNG CHILD RESTRAINT (WITH CHILD SEATS OR BOOSTERS), SPECIAL VERBIAGE FOR RESTRAINING OLDER CHILD IS INCLUDED IN THE OWNER'S MANUAL. ALSO, THE SUGGESTED SEAT BELT FIT/ROUTING FOR ADULTS, IRRESPECTIVE OF SEATING POSITION, IS DESCRIBED IN THE OWNER'S MANUAL TEXT.
Potential 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 1-800-732-5493.
Brakes
Summary
On certain vehicles, the hydraulic brake booster's pressure accumulator may crack and/or separate from the Hydro-Boost assembly during normal vehicle operating conditions. If a separation occurred and the hood of the vehicle was open, fragments from the accumulator could cause injury to people in the immediate area. In addition, 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. Correction: Dealers will test and, if necessary, replace the Hydro-Boost assembly.
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.
Potential 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.
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.
Potential 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.
Other
Summary
On certain vehicles, the galvanized-braided-steel tailgate support cables used to support the tailgate in the full open (horizontal) position can corrode over time and fracture when loads are applied to them. Tailgate support cable corrosion may not be visible because of the plastic sheathing covering the cable. If one cable fractured, the remaining cable may retain the tailgate in a horizontal position. If the remaining cable was weakened by corrosion, it could fracture within moments of the first cable fracture. If both cables fractured, the tailgate would suddenly drop approximately 10 degrees and strike the top surface of the rear bumper. If anyone is sitting or standing on the horizontal surface of the tailgate when both cables fracture, they could fall and be injured. On vehicles without a rear bumper, the tailgate may drop to a lower position. Correction: Dealers will replace the existing galvanized support cables with stainless steel support cables.
SERVICE BRAKES, HYDRAULIC
Summary
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.
Potential 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.
Brakes
Summary
On certain vehicles, the relief valve o-ring seal within the brake hydro-boost module could fail. If this happens during braking applications, the driver may be able to hear an engine compartment noise similar to the sound that occurs when the steering wheel is turned to a full stop position. The driver could also experience a slight increase in steering efforts while braking and parking. Under certain driving conditions, a slight increase in the applied brake pedal effort may be required to achieve the same vehicle deceleration rate as prior to the seal failure. Correction: Dealers will inspect the hydro-boost module, and replace it, if necessary.
Generated by Cardog • December 11, 2025
2004 Chevrolet Avalanche
Safety Recalls & Notices
12 Active Recalls
Requires attention
