Rust or structural corrosion on the 2004 GMC Sierra 1500
Only 5 reports for this mode came with an odometer reading, which is too few for percentiles to mean anything. The page is here because someone linked to it; treat the figures as anecdotes, and see the full report for this year instead.
When rust or structural corrosion gets reported
There are 5 reports of rust or structural corrosion on the 2004 GMC Sierra 1500, 5 with a mileage attached. That is too few to place the failure on the odometer with any confidence.
A part like this is normally expected to survive 120,000 miles. It is the 16th most-reported problem on this model year.
The whole distribution
| 10th | 25th | Median | 75th | 90th |
|---|---|---|---|---|
| — | — | 100,000 miles | — | — |
Read the 10th percentile as “one report in ten arrived this early”. Exact figures are shown in this table because it is the table of record; everywhere else on the site they are rounded to the precision the sample can carry.
What a percentile can and cannot tell you here
These five numbers describe the readings owners gave, in order. The median is the middle one: half the reports arrived below it. The 10th and 90th are the edges of the bulk of the distribution, and the distance between them is the part worth reading. A tight spread — say 70,000 to 95,000 miles — points at something that wears out on a schedule, and the schedule is knowable. A wide one, 20,000 to 190,000, points at a fault that hits some cars and never troubles others, which means the mileage on the listing in front of you tells you very little about your odds.
What these figures are not is a survival curve. Every reading here comes from a car whose owner filed a complaint, so the sample contains only failures: it cannot say what share of the fleet made it past 150,000 miles untouched, because those owners had nothing to report. Nor is the mileage the moment of failure — it is the odometer reading as recalled at the time of filing, which may be weeks later and is sometimes rounded to the nearest ten thousand by the person typing it.
Percentiles are shown at all only once 8 readings exist for the vehicle and mode. Below that the middle of a handful of numbers is noise wearing a decimal point, so the figures are withheld rather than dressed up.
What happens, and what it costs
Putting it right typically runs $500–$6,000 at an independent US shop. That range is an editorial estimate held in this site's failure-mode catalogue, not a figure from NHTSA, and it is a repair cost rather than a diagnosis cost.
The same failure on other years
The same failure is reported on 10 model years of this car. It shows up earliest on the 2006, at a median of 55,000 miles, and latest on the 1999 at 150,000 miles.
By volume the 2003 carries the most reports, with 14; the 2004 has 5. A mode that appears across most years of a model is usually a design choice rather than a bad batch.
If one year stands out to the left, that is the year to avoid; if the whole line sits at a similar mileage, this is wear rather than a defect in one production run.
Tick median reported mileage Solid middle half of reports Faint 10th to 90th percentile Colour how bad the failure is when it happens
What owners wrote
Verbatim from NHTSA complaint narratives, trimmed for length. The mileage is the one the owner gave.
While exiting the highway driver pressed brake pedal which sank all the way to the floor with approx 5 percent braking power. Driver lifted off and reapplied the brakes in an attempt to fix problem at this point a dash light and alarm illuminated to warn of brake issues; braking power was still only 5 percent. Driver was able to stop before an accident occurred but only because of light traffic and plenty of run off area. Upon inspection of vehicle it was evident that the brake lines had corroded and ruptured under the drivers door. Vehicle was taken to dealership where 6 brake lines were replaces due to corrosion. Vehicle was not driven in northern winters and has not been on any beaches. *tr
Got in my car and proceeded to go down the road I was doing about 45 miles an hour I hit the brakes to slow down and the brake pedal went the whole way to the floor after I got stopped and checked it out the brake lines are completely rusted through. *tr
04 gmc sierra 1500 extended cab front steel brake lines corrosion/rusted and burst caused sudden fluid leakage and failure to stop placed me in a dangerous/hazardous situation. Finding a reliable shop, expensive towing and repairs caused tremendous burden and inconvenience. *tr
Also reported on the 2004 GMC Sierra 1500
Instrument cluster or gauge failure
Other electrical problem
Loss of braking
Other brake problem
Brake line, hose or caliper failure
Steering column or shaft failure
How far this goes
This page is kept out of search results because 5 reports is not enough to publish percentiles from. It stays reachable because somebody looking at this exact car would rather see the reports than be told there are none.
Complaints are voluntary, so 5 is a floor and not a count of affected cars. Mileages are typed in by owners and cluster on round numbers. And the mode itself is assigned by software reading the complaint text, which is reliable in bulk and fallible one report at a time.
Questions this page answers
At what mileage does rust or structural corrosion happen on the 2004 GMC Sierra 1500?
Across 5 owner reports that included an odometer reading, half were filed by 100,000 miles. A quarter were filed before — and a quarter after —. These are the mileages owners reported when they complained, not a prediction for any individual car.
How common is rust or structural corrosion on the 2004 GMC Sierra 1500?
5 reports have been filed with NHTSA, about 5.1 per 1,000 vehicles. Complaints are voluntary, so this is a floor rather than a count of affected cars.
What this is and is not. These are the mileages at which owners chose to complain to a federal agency, which is not the same as the mileage at which the part fails on every car. It skews toward failures that happened outside warranty, cost real money, or frightened someone. It is still the only public dataset that carries failure mileage at all, and the shape of a few hundred readings is informative even when a single one is not. Methodology · JSON · this failure on other cars
Source Owner complaints and recall records published by the US National Highway Traffic Safety Administration, model years 1996–2027 Figures rebuilt Published by AtWhatMileage How every figure is computed