One problem related to fuel pump has been reported for the 2004 Chevrolet Tahoe. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2004 Chevrolet Tahoe based on all problems reported for the 2004 Tahoe.
Smell of fuel for about a week brought it to evans automotive st Aug. Fl. 32080. They contacted me and told me flaw in design of tank water gets up on top of tank and sits there. This rots out sending unit and fuel pump as well as locking studs that hold down this one piece unit. Tank is plastic but studs that lock in part are metal they rot making tank very very dangerous. They said I was very lucky the truck did not catch fire with my family and I in it. They said the smallest spark would have caused the truck to catch fire. To repair this it is going to run about 1500. 00. Or try to find a used tank in good shape. They are telling me weather new or used this is going to happen again over time. The flaw is that there is no way for water to get out of bowl shape where fuel pump is. That makes it very dangerous. When looking for tank it says tank from 2003 to 2009 fit. That means other trucks have same problem such as chev,GMC,pickups,searria,silverdos,youkon ect. . . . . . . . Please look into this before someone or some family gets killed. Thank you!!!!!.