2004 Chevrolet Silverado 2500 HD REPAIR MANUAL -- HOW TO FIX YOUR CAR OR TRUCK

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2004 Chevrolet Silverado 2500 HD CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Chevrolet REPAIR SHOPS DON'T WANT YOU TO KNOW

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Get Full Access Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2004 Chevrolet Silverado 2500 HD car and truck repair procedures including Chevrolet engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up & drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix your Chevrolet Silverado 2500 HD automobile. Try the Automotix DIY solution today!
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Using the Automotix DIY repair procedures will save you hundreds and even thousands of dollars! In addition, it will save you hours of touring the city searching for Chevrolet mechanics you can trust. The Automotix DIY solution is particularly affordable. A full access to the entire DIY repair procedures and diagrams for your 2004 Chevrolet Silverado 2500 HD vehicle will cost less than a single gallon of gas. Here are some of the DIY repair tips and procedures you will find here:

A/C & HEATER SERVICE PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES

Orifice Tube/Expansion Valve Locations -> Domestic Light Trucks & Vans -> 2003-04
Vehicle: 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL

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BRAKE SERVICE PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES

Disc Brakes -> Delco Dual Piston Sliding Caliper -> Troubleshooting -> Brake Rattle -> Brake Roughness Or Chatter; Pedal Pumping -> Caliper Brake Fluid Leak -> Excessive Pedal Effort -> Excessive Pedal Travel -> Heavy Brake Drag -> No Braking Effect When Brake Pedal Is Depressed -> Pull, Uneven Or Grabbing Brakes -> Rear Brakes Locking On Application
Vehicle: 2004 Chevrolet Silverado 2500 HD 6.0 V8 GAS

Excessive Pedal Travel

  • Worn brake linings.
  • Disc pads knock back after cornering or rough road travel.
  • Piston and linings not properly seated or positioned.
  • Insufficient fluid in system.
  • Loose wheel bearing adjustment.
  • Damaged or worn caliper piston seal.
  • Improper booster pushrod adjustment.
  • Pads out of flat more than .005 inch.
  • Rear brake automatic adjusters inoperative.
  • Improperly ground rear brake shoes.

Brake Roughness Or Chatter; Pedal Pumping

  • Excessive lateral runout of rotor.
  • Rotor excessively out of parallel.

Excessive Pedal Effort

  • Frozen or seized pistons.
  • Brake fluid, oil or grease on ...

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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES

General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Fuel Filter Replacement -> 6.6L Diesel Engine
Vehicle: 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL

On models equipped with fuel injected engines, relieve fuel system pressure as outlined under "Fuel System Pressure Relief."

On models equipped with metal collar quick disconnect connectors, GM tool No. J37088-A, or equivalent, will be required to disconnect the connector. Prior to reconnecting the connector, apply a few drops of clean motor oil to the male pipe ends.

On models equipped with plastic collar quick disconnect connectors, squeeze the connector plastic retainer release tabs to release the connector. Prior to reconnecting the connector, apply a few drops of clean motor...

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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES

DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble
Vehicle: 2004 Chevrolet Silverado 2500 HD 8.1 V8 GAS

Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal.

Disassemble

  • Support propeller shaft in a line horizontal with table of a press.
  • Mark propeller shaft in order to show which end connects to transmission and which end goes to rear axle.
  • On models equipped with external snap ring retainers, proceed as follows:
    • Disassemble snap rings by ...

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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES

Alternator, Replace
Vehicle: 2004 Chevrolet Silverado 2500 HD 6.0 V8 GAS

  • Disconnect battery ground cable.
  • Remove air inlet duct, if required.
  • Disconnect terminal plug and battery lead connections from back of alternator.
  • Remove upper fan shroud mounting bolts and fan shroud.
  • Remove accessory drive belt using suitable 3/8 i...

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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES

Cabin Air Filter Service -> General Motors Corp./Saturn -> 1999-2007 Silverado, Sierra, 2000-07 Denali, Suburban, Tahoe, Yukon, Yukon XL, 2001-07 Escalade & 2002-07 Avalanche
Vehicle: 2004 Chevrolet Silverado 2500 HD 6.0 V8 GAS

Under normal operating conditions the cabin air filter should be replaced every 15,000 miles. In dusty areas change the cabin air filter more often.

  • Remove the righthand instrument panel hush panel.
  • Remove the A/C and heater modul...

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MAINTENANCE LAMP RESET PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES

General Motors Corp./Saturn Trucks -> Water In Fuel Or Drain Fuel Filter Warning Lamp -> Diesel Engine
Vehicle: 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL

The Water In Fuel indicator should light when excessive water has entered the fuel system. As the fuel filter becomes plugged, a low pressure sensor activates the lamp. The lamp should light during engine starting as a bulb inspection. Once the engine has started, the lamp should go off. If the lamp is lit intermittently, drain fuel filter. If lamp remains lit, drain fuel filter. If the lamp still remains on after fuel filter has been drained, replace fuel filter. If lamp is lit dur...

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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES

Radiator, Replace
Vehicle: 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL

  • Drain coolant into a suitable container.
  • Remove radiator air upper baffle retainers, then upper air baffle, Fig. .
  • Remove inlet and outlet hoses from radiator.
  • Lift lower fan shroud upward to disengage from clips, then remove lower fan shroud from vehicle.
  • Remove surge tank hose from radiator
  • Remove and discard radiator quick connect fittings as follows:
    • Pull caps back along pipe, then holding one leg o...

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SERPENTINE BELT SERVICE PROCEDURES FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES

Serpentine Drive Belt, Replace
Vehicle: 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL

  • Rotate tensioner to release belt tension using a 1/2 inch breaker bar with a 5/8 inch socket placed on tensioner pulley, then remove belt.
  • Route be...

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COMPONENT LOCATION DIAGRAMS FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES

Component location diagrams for most 2004 Chevrolet Silverado 2500 HD cars and light trucks sold in the U.S. from 1990+.

Door Latch Assembly Passenger Door Jamb Diagram for 2004 Chevrolet Silverado 2500 HD  6.0 V8 GASDoor Latch Assembly Passenger Door Jamb Diagram for 2004 Chevrolet Silverado 2500 HD 6.0 V8 GAS

Components on diagram:
  • Door
  • Door Jamb Switch Passenger Connector
  • Door Lock Actuator Passenger Connector
  • Left Door,Inside View Diagram for 2004 Chevrolet Silverado 2500 HD  6.6 V8 DIESELLeft Door,Inside View Diagram for 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL

    Components on diagram:
  • Door
  • Outside Rearview Mirror
  • Speaker Connector
  • Window Motor Connector
  • Outside Rearview Mirror Switch Connector
  • CLICK HERE TO GET FULL ACCESS TO 2004 Chevrolet Silverado 2500 HD PARTS/COMPONENTS LOCATION DIAGRAMS!

    WIRING DIAGRAMS FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES

    OEM drawn wiring diagrams for most 2004 Chevrolet Silverado 2500 HD cars and light trucks sold in the U.S.

    2004 Chevrolet Silverado 2500 HD  6.6 V8 DIESEL Wiring Diagram2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL Wiring Diagram

    Components on diagram:
  • Brake Pedal Position Sensor
  • Electro Hydraulic Power Steering Module
  • Steering Wheel Speed Position Sensor
  • 2004 Chevrolet Silverado 2500 HD  6.6 V8 DIESEL Wiring Diagram2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL Wiring Diagram

    Components on diagram:
  • Cigar Lighter
  • Auxiliary Power Outlet Front
  • Auxiliary Power Outlet Console
  • Auxiliary Power Outlet Bin
  • CLICK HERE TO GET FULL ACCESS TO 2004 Chevrolet Silverado 2500 HD WIRING DIAGRAMS!

    TECHNICAL SERVICE BULLETINS FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES

    OEM TSB listings for most 2004 Chevrolet Silverado 2500 HD cars and light trucks sold in the U.S. from 1985+.

    Document: 6.6L LB7, LLY Duramax Diesel Engine Cylinder Head Gasket Missing Thickness Grade Markings-Inspect Block for Stampings
    Vehicle: 2004 Chevrolet Silverado 2500 HD 6.6 V8 DIESEL

    Auto Systems:
  • Diesel Engines
  • Document: Revised General Motors New Vehicle Tire Warranty Program
    Vehicle: 2004 Chevrolet Silverado 2500 HD 6.0 V8 GAS

    Auto Systems:
  • Labor Times, Manuals, Warranty, Aids
  • Wheels, Tires, Wheel Bearings, Seals, Hubs
  • CLICK HERE TO GET FULL ACCESS TO 2004 Chevrolet Silverado 2500 HD TECHNICAL SERVICE BULLETINS!

    COMPONENT/PARTS SPECIFICATIONS FOR 2004 Chevrolet Silverado 2500 HD AUTOMOBILES

    BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2004 Chevrolet Silverado 2500 HD cars and light trucks sold in the U.S. and Canada from 1970+.

    • Brake caliper mounting bolt torque
    • Brake drum runout, machining, & discard specs
    • Minimum brake lining thickness.
    • Brake rotor runout, parallelism, machining, discard, & finish specs

    A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2004 Chevrolet Silverado 2500 HD cars and light trucks sold in the U.S. and Canada from 1980+.

    • Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap

    COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.

    PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules

    QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2004 Chevrolet Silverado 2500 HD cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.

    • Automatic transmission/transaxles capacities, lubricant recommendations
    • Differential/final drive capacities, lube recommendations, grades, & viscosities
    • Final drive fill & drain plug torques
    • Number of lubrication fittings & plugs
    • Power steering, brake, & clutch fluid recommendations
    • Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
    • Number of lubrication fittings & plugs
    • Power steering, brake, & clutch fluid recommendations
    • Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
    • Severe service maintenance & interval recommendations
    • Tire sizes, wheel nut/bolt torque, pressures & rim sizes
    • Transfer case capacities, lube recommendations, grades, & viscosities

    TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2004 Chevrolet Silverado 2500 HD cars and light trucks sold in the U.S. and Canada from 1980+

    • Airflow sensor electrical specifications
    • Tensioning specifications for systems with automatic tensioners
    • Barometric pressure sensor specs
    • Battery group number and cranking performance
    • Crankshaft & camshaft position sensor resistance
    • Engine compression pressures
    • Coolant temperature sensor specs
    • Computer advance.
    • Diesel fuel temperature sensor resistance.
    • Distributor advance specifications
    • Ignition pickup coil resistance
    • Exhaust gas recirculation temperature sensor resistance
    • Engine fastener torque values
    • Firing order diagrams
    • Fuel system pressures
    • Generator (alternator) specs
    • Intake air temperature sensor specs
    • Ignition coil specifications
    • Fuel injector resistance
    • Engine idle speeds
    • Knock sensor resistance
    • Manifold absolute pressure sensor specs
    • Mixture control solenoid resistance
    • Voltage regulator specs
    • Spark plug applications & gaps
    • Starter motor electrical specs.
    • Tensioning specifications for systems without automatic tensioners
    • Throttle body temperature sensor resistance
    • Ignition timing in degrees at rpm
    • Transmission oil temperature sensor resistance
    • Throttle position sensor specs
    • Vacuum sensor valve specs

    CLICK HERE TO GET FULL ACCESS TO 2004 Chevrolet Silverado 2500 HD SPECIFICATIONS DATA!

    Shop online for auto body parts, engines, wheels, lights...

    Click here to view more details2011 Chevrolet Silverado 2500 HD Bumper End, Rear, Driver Side, Without parking aid sensor holes; Ensures precise and perfect fit for a reliable and efficient performance; Adds unique and distinctive styling that gives your vehicle a custom look; With 1-year limited Martins warranty..

    Source: Auto Body Parts Store

    $244.89

    Click here to view more details2008 Chevrolet Silverado 2500 HD Mirror, Passenger Side, Convex glass; Non-folding; Telescopic type; With plate; Without glass; A high quality, direct fit OE replacement mirror; Backed by 2-year Kool Vue limited warranty..

    Source: Auto Body Parts Store

    $99.26

    Click here to view more details about 2005 Chevrolet S10 Blazer 15" x 7" Steel Wheel2005 Chevrolet S10 Blazer 15" x 7" Steel Wheel, Steel Wheel; 15 X 7; 8 Slots; 5 Lug; 4.75 Inch BP; Ident TCJ; Flat Black, , .

    Source: Wheels / Rims, Mirrors & Lights Store

    $69.50

    Click here to view more details1993 Jeep Cherokee L4, 2.5 L, 150 CID Rebuilt Engine, Block #532, 403, Head #403, 117 Crank #904, Crank snout 2.125", Oil bypass in filter, not in block, FI only, Warranty: 3-Year/100,000 Mile, .

    Source: Rebuilt Engines Store

    $1,297.00

    Click here to view more details2011 Chevrolet Silverado 2500 HD Used Air Flow Meter/Sensor, 6.6, AUTO, 4X4 6.6L, Very Good.

    Source: Used Auto Parts Store

    $110.00

    Click here to view more details2006 Chevrolet Silverado 2500 HD Used Rear Axle Assembly, 8.1, AUTO, 4X4 FULL-FLOATING AXLE, 11.5 RING GEAR, 4.10 RATIO (OPT GT5), Very Good.

    Source: Used Auto Parts Store

    $803.00
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