2004 Chevrolet Express problems
The Chevrolet Express (also known as the GMC Savana) is a series of full-size vans produced by General Motors since 1996. The successor to the Chevrolet G-series van, the Express is produced in passenger and cargo variants. Alongside the standard van body, the line is offered as a cutaway van chassis; the latter vehicle is a chassis cab variant developed for commercial-grade applications, including ambulances, buses, motorhomes, and small trucks.
In production for a single generation since 1995, over 2.5 million examples of the Express and the Savana have been produced. One of the longest-produced designs in American automotive history, the Express/Savana are rivaled only by the Jeep Wagoneer and Dodge Ram Van for longevity.
Since 1995, General Motors has assembled the Express and Savana at its Wentzville Assembly facility (Wentzville, Missouri). Also, since 2017, GM has sourced commercial cutaway-chassis production from Navistar through its Springfield Assembly Plant (Springfield, Ohio).
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Common 2004 Chevrolet Express problems
Based on complaints from owners of the Chevrolet Express 2004, several common problems have been reported. Here is a detailed list of these issues:
- Seat Belts: Front: Buckle Assembly: Another recall was announced on 04/16/2004 for Chevrolet Express 2004 vans that failed to conform to federal safety standards for seat belt assemblies. These vehicles may have been produced with seat belt buckle assemblies containing a latch with a brittle condition that may not withstand the force requirements of the standard. Dealers were instructed to replace the safety belt buckle to rectify this issue.
- Power Train: Automatic Transmission: Lever and Linkage: Column Shift: Certain Chevrolet Express 2004 vans were built with a transmission shift cable assembly that may separate, leading to a discrepancy between the transmission shift lever position and the transmission indicator. Dealers were required to inspect the transmission shift cable assembly and replace it if necessary to address this problem.
These issues highlight safety and functionality concerns with the Chevrolet Express 2004 model, emphasizing the importance of addressing recalls promptly to ensure the safety and reliability of the vehicle.
Is the Chevrolet Express a reliable van?
The Chevrolet Express 1500 Reliability Rating is 3.0 out of 5.0, which ranks it 9th out of 21 for commercial vans. The average annual repair cost is $963 which means it has poor ownership costs.
How long do Chevy Express engines last?
If you have a 4.3 V6 250,000 miles would be good. If you have a 4.8L, 5.3L or 6.0L V8 all are LS based engines. Those engines if cared for properly 300,000 is not uncommon. If you drive it like you stole it all the time you will be lucky to make 150,000 miles.
How many miles does a Chevy Express get?
Gas Mileage 7/10 – Fuel economy is okay at up to 20 MPG, offering 620 miles of range out of the 31 gallon tank. Gas costs are similar to other vans, at $369 per month. Value 8/10 – The 2019 Chevrolet Express is cheaper than a lot of other full size vans with reasonable depreciation rates, making it an attractive value.
What is the recall on the Chevy Express van?
Recall # N202325160 Date: 03/18/2021 Recall: General Motors, LLC is recalling certain 2021 Chevrolet Express and GMC Savana vehicles equipped with 6.6L gasoline engines. The positive battery cable terminals may contact a fuse block assembly attachment post and cause an electrical short circuit.
Is the Chevy Express reliable?
The Chevrolet Express 3500 Reliability Rating is 2.5 out of 5.0, which ranks it 13th out of 21 for commercial vans. The average annual repair cost is $1,013 which means it has poor ownership costs. The frequency of repairs is average, but when issues do arise, they are more likely to be severe than with other models.
How long do Chevy Express engines last?
If you have a 4.3 V6 250,000 miles would be good. If you have a 4.8L, 5.3L or 6.0L V8 all are LS based engines. Those engines if cared for properly 300,000 is not uncommon. If you drive it like you stole it all the time you will be lucky to make 150,000 miles.
Why is my Chevy Express overheating?
Cooling System Leak – This is probably the most common cause of an overheating engine. If any component in your cooling system–which includes your radiator, hoses, water pump, head gasket, and thermostat casket–starts to leak, you're in trouble.
What engines are in the Chevy Express?
6.6L V8. Max trailering weight of up to 9,600 lbs.
2004 Chevrolet Express car problems categorized by type of issue
After analyzing all complaints sent to the NHTSA and researching popular Chevrolet Express problems, we found that the most common problems with these 2023 model year vehicles are:
- Service brakes problems
- Hydraulic problems
- Fuel/propulsion system problems
- Steering problems
- Structure problems
The graph below shows statistics for all 2004 Chevrolet Express vehicle components and the number of complaints received.
Latest 25 complaints 2004 Chevrolet Express
The NHTSA has received 57 complaints about various vehicle components related to the 2004 Chevrolet Express. Below are the 25 most recent complaints reported for 2004 Chevrolet Express vehicles.
FUEL/PROPULSION SYSTEM PROBLEM
- Date Of Incident: 2021-12-04
- VIN: 1gagg25u841
- Components: FUEL/PROPULSION SYSTEM
- Summary: NHTSA Campaign Number: 12V388000. I have this problem. A leaking fuel line due to corrosion. I drive in the Cascade MT's of Washington state. my line now leaks excessively on fill up.
SUSPENSION,SERVICE BRAKES PROBLEM
- Date Of Incident: 2021-11-12
- VIN: 1GAHG39U341
- Components: SUSPENSION,SERVICE BRAKES
- Summary: This vehicle was sold for use over US highways, as "repairable condition". After going to a mechanic shop, I was advised, because of sever rust the rear leaf spring hangers were completely rusted thru, the rear axle assembly could come off or the frame could break in half, by just going over say, a railroad crossing. The mechanic said they would not repair this vehicle for use to drive on roads. I am requesting a local representative to help evaluate if this vehicle is safe to travel on Oklahoma roads.
FUEL/PROPULSION SYSTEM PROBLEM
- Date Of Incident: 2018-12-03
- VIN: 1GBJG31U841
- Components: FUEL/PROPULSION SYSTEM
- Summary: MY 2004 CUTAWAY CHEVY SOLD AS A 2005 FOUR WINDS HAS THE EXACT PROBLEM FOR THIS RECALL. RECALL NUMBER 12V388000 RECALL DATE 08/08/2012 COMPONENT FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP SUMMARY GENERAL MOTORS (GM) IS RECALLING CERTAIN MODEL YEAR 2003-2004 CHEVROLET EXPRESS AND GMC SAVANA VEHICLES, EQUIPPED WITH A LEFT SIDE CARGO DOOR, AND ORIGINALLY SOLD OR CURRENTLY REGISTERED IN CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA. WATER AND ROAD CONTAMINANTS MAY BECOME TRAPPED IN THE PROTECTIVE CONDUIT THAT COVERS THE FUEL FILLER PIPE AND MAY CAUSE THE PIPE TO CORRODE. CONSEQUENCE SIGNIFICANT CORROSION MAY ALLOW FUEL TO LEAK DURING REFUELING, AND IN THE PRESENCE OF AN IGNITION SOURCE; THERE IS AN INCREASED RISK OF FIRE. WHAT OWNERS SHOULD DO GM WILL NOTIFY OWNERS, AND DEALERS WILL INSTALL A NEW FUEL FILLER NECK, FREE OF CHARGE. THE SAFETY RECALL BEGAN ON OCTOBER 1, 2012. OWNERS MAY CONTACT THE CHEVROLET OWNER CENTER AT 1-866-694-6546 AND GMC AT 1-866-996-9463. THE EXPRESS 1500 I OWN IS CURRENTLY EXHIBITING THIS EXACT ISSUE, AND ALTHOUGH SOLD IN CA IN 2005, BASE VAN WAS MANUFACTURED IN INDIANA MODIFIED BY THOR MOTORHOMES. THIS STATE IS LISTED IN THE RECALL ABOVE. I'M AFRAID TO DRIVE IT, CAN'T AFFORD TO FIX THE ISSUE BEING DISABLED VET ON SMALL SSDI INCOME. IVE THE FEELING IT'S THE SAME MODEL RECALLED, BUT OF COURSE CHEVY WILL NOT REPAIR IT BECAUSE IT IS NOT SPECIFICALLY ON RECALL LIST LIKE THE LEFT SIDE CARGO DOOR MODELS THAT ARE BEING REPAIRED BY THE CHEVROLET GM DEALERS? PLEASE HELP
FUEL/PROPULSION SYSTEM PROBLEM
- Date Of Incident: 2016-11-08
- VIN: 1GBFG15T541
- Components: FUEL/PROPULSION SYSTEM
- Summary: TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS. WHILE THE VEHICLE WAS STATIONARY, FUEL SPILLED ONTO THE GROUND. IT WAS DIAGNOSED THAT THE FILLER NECK WAS CORRODED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE. THE FAILURE MILEAGE WAS 148,000. UPDATED 04/11/2017*JS
VISIBILITY/WIPER PROBLEM
- Date Of Incident: 2016-09-11
- VIN: 1GCHG39U141
- Components: VISIBILITY/WIPER
- Summary: TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS. WHILE THE VEHICLE WAS PARKED THE REAR DRIVER'S SIDE WINDOW FELL OUT OF PLACE. THE CONTACT STATED THAT ALL THE WINDOWS ON THE VEHICLE WERE LOOSE. THERE NO WARNING LIGHTS ILLUMINATED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE ISSUE. THE FAILURE MILEAGE WAS 33,000. UPDATED 01/31/17*LJ CONSUMER STATED DRIVERS SIDE REAR SEAT LOWER WINDOW BROKE. GLUE CAME OFF MANUFACTURED WINDOW MADE BY C.R. LAURENCE CO, INC. WINDOW WAS REPLACED 11/08/16. UPDATED 6/22/18*JB
SERVICE BRAKES PROBLEM
- Date Of Incident: 2014-04-07
- VIN: 1GCGG25V441
- Components: SERVICE BRAKES
- Summary: TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 2500. THE CONTACT STATED THAT WHEN THE BRAKES WERE APPLIED, THE VEHICLE SHOOK VIOLENTLY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE THE BRAKE PADS AND ROTORS WERE REPLACED; HOWEVER, THE FAILURE CONTINUED. THE CONTACT HAD TO APPLY EXTREME FORCE TO THE BRAKE PEDAL TO ENSURE THAT THE VEHICLE CAME TO A COMPLETE STOP. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBERS: 05V043000 (SERVICE BRAKES, HYDRAULIC) AND 04V045000 (SERVICE BRAKES, HYDRAULIC). THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 115,000.
STRUCTURE PROBLEM
- Date Of Incident: 2016-09-03
- Fire: 1
- VIN: 1GCHG35U941
- Components: STRUCTURE
- Summary: THE VAN WAS PARKED IN MY DRIVEWAY STATIONARY. IT CAUGHT FIRE AND PROCEEDED TO BURN COMPLETELY FOR UNKNOWN REASONS. THE WEBSITE STATES THIS VIN NUMBER IS NOT INCLUDED IN ANY RECALLS BUT THE VEHICLE TYPE HAS A RECALL LISTED THAT STATES IT COULD BE A FIRE HAZARD.
SEAT BELTS PROBLEM
- Date Of Incident: 2016-08-09
- VIN: 1GBFG15XX41
- Components: SEAT BELTS
- Summary: TWO REAR BUCKET SEAT BELT CABLES HAVE BROKEN WITHOUT IMPACT.
SERVICE BRAKES PROBLEM
- Date Of Incident: 2016-04-05
- VIN: 1GBHG31V341
- Components: SERVICE BRAKES
- Summary: 2004 CHEVROLET EXPRESS COLLINS SCHOOL BUS WHILE DRIVING AT 15 MPH ON AN INCLINED RURAL COUNTRY ROAD ATTEMPTING TO BRAKE NOTICED PEDAL EXTENDED TO THE FLOOR AND WAS STOPPED BY FURTHER DOWN SHIFTING AND APPLYING EMERGENCY BRAKE. INFORMED BY REPAIR SHOP THE RIGHT FRONT HYDRAULIC LINE RUBBED THROUGH THE METAL BRAKE LINE CAUSING THE FAILURE. FAILURE MILEAGE 43,997.
FUEL/PROPULSION SYSTEM PROBLEM
- Date Of Incident: 2015-07-05
- VIN: 1GBFG15T941
- Components: FUEL/PROPULSION SYSTEM
- Summary: THE FUEL FILLER TUBE LEAKS FUEL, IS CORRODED. AND ALSO THE REAR FUEL TANK STRAP, AT THE TOP OF THE CHASSIS IS ALSO CORRODED, AND THE FUEL TANK IS HANGING DOWN, CAUSING A RISK AND FIRE HAZZARD AS IT IS VERY CLOSE TO THE DRIVESHAFT.
TIRES PROBLEM
- Date Of Incident: 2015-08-27
- VIN: 1GCHG39U741
- Components: TIRES
- Summary: TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 3500 EQUIPPED WITH TOYO OPEN COUNTRY H/T TUFF DUTY TIRES, SIZE: LT245/75/R16 TIRES. WHILE DRIVING 65 MPH, THE CONTACT HEARD A LOUD NOISE AND THE REAR DRIVER SIDE TIRE BLEW OUT. THE VEHICLE WAS TOWED TO A DEALER WHO DIAGNOSED THAT ALL FOUR TIRES HAD CRACKS AND NEEDED TO BE REPLACED. IN ADDITION, MULTIPLE PARTS NEEDED TO BE REPLACED. THE TIRES WERE REPLACED, BUT THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE FAILURE MILEAGE WAS 120,187 AND THE TIRE FAILURE MILEAGE WAS 25,982.
AIR BAGS,STRUCTURE,ENGINE PROBLEM
- Date Of Incident: 2013-11-21
- Number Of Injuries: 1
- Crash: 1
- VIN: 1GNFG15T641
- Components: AIR BAGS,STRUCTURE,ENGINE
- Summary: I WAS TRAVELING EAST THRO AN INTERSECTION WHEN A TRUCK ON THE MY RIGHT RAMMED ME IN THE FRONT RIGHT SIDE OF MY CAR.I FELT THE CAR SPIN AND THE TRUCK ENDED UP IN MY RIGHT REAR BUMPER AND WHEN I CAME TO A STOP BOTH AIRBAGS DEPLOYED AND I WAS INJURED AND THE AIRBAGS EXPLODED AND I HAVE EYE DAMAGE TO MY RIGHT EYE AND NECK INJURY AND BACK INJURY. STILL SEEING SPINE DR. AND EYE DR EVERY 6 MONTHS. *TR
ENGINE PROBLEM
- Date Of Incident: 2014-06-06
- Fire: 1
- VIN: 1GBJG31U841
- Components: ENGINE
- Summary: ENGINE EXHAUST MANIFOLD BROKEN BOLTS,HAS 3 AT THIS POINT AND TIME. THIS CAUSES THE EXHAUST TO LEAK INTO DRIVERS COMPARTMENT. *TR
POWER TRAIN PROBLEM
- Date Of Incident: 2013-01-16
- VIN: 1GNFG15T141
- Components: POWER TRAIN
- Summary: TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS. THE CONTACT STATED THAT WHILE ATTEMPTING TO SHIFT INTO PARK, THE LINKAGE POPPED OFF PREVENTING THE VEHICLE FROM BEING SHIFTED INTO PARK. THE EMERGENCY BRAKE WAS ENGAGED IN ORDER TO PREVENT THE VEHICLE FROM MOVING. THE VEHICLE WAS DIAGNOSED WITH A FAILED CABLE ASSEMBLY THAT NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 120,000 AND THE CURRENT MILEAGE WAS 136,000.
SERVICE BRAKES PROBLEM
- Date Of Incident: 2012-08-15
- VIN: 1GNFG15T141
- Components: SERVICE BRAKES
- Summary: TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS. THE CONTACT STATED THAT WHILE DRIVING 5 MPH AND DEPRESSING THE BRAKE PEDAL, THE ABS SYSTEM PREVENTED THE VEHICLE FROM BRAKING PROPERLY AND THE ABS WARNING LIGHT ILLUMINATED. IN ONE OCCASION, THE VEHICLE FAILED TO STOP AND PROCEEDED THROUGH THE INTERSECTION DURING A RED LIGHT. THE VEHICLE WAS TAKEN TO A PRIVATE MECHANIC WHERE IT WAS DIAGNOSED THAT THE BRAKE SENSORS AND THE ABS MAIN CONTROL SYSTEM NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS REPAIRED BUT THE FAILURE RECURRED. THE FAILURE MILEAGE WAS 110,000 AND THE CURRENT MILEAGE WAS UNKNOWN.
STRUCTURE PROBLEM
- Date Of Incident: 2010-01-06
- VIN: 1GCHG35U041
- Components: STRUCTURE
- Summary: TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 3500. THE CONTACT STATED THAT THE PASSENGER AND DRIVER SIDE DOOR HINGES WERE FRACTURED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 25,000.
SERVICE BRAKES PROBLEM
- Date Of Incident: 2013-11-14
- VIN: 1GAHG39UX41
- Components: SERVICE BRAKES
- Summary: TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 3500. THE CONTACT STATED WHILE DRIVING DOWN A MOUNTAIN ROAD APPROXIMATELY 45 MPH THE BRAKE PEDAL WAS DEPRESSED AND THE VEHICLE BEGAN TO VIBRATE EXCESSIVELY AND THE BRAKE DISCS OVERHEATED. THE FAILURE WAS NOT DIAGNOSED NOR WAS THE VEHICLE REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE DEFECT. THE APPROXIMATE FAILURE MILEAGE WAS 128,000. UPDATED 08/11/14*LJ UPDATED 08/18/2014 *JS
FUEL/PROPULSION SYSTEM PROBLEM
- Date Of Incident: 2013-11-07
- VIN: 1GCHG35U241
- Components: FUEL/PROPULSION SYSTEM
- Summary: TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 3500. THE CONTACT STATED THE FUEL FILLER NECK TUBE WAS CORRODED, CAUSING FUEL TO LEAK WHEN REFUELING THE VEHICLE. THE CONTACT REFERENCED NHTSA CAMPAIGN NUMBER: 12V388000 (FUEL SYSTEM, GASOLINE) BUT WAS ADVISED BY THE MANUFACTURER THAT THE VIN WAS NOT INCLUDED IN THE RECALL. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 130,000.
POWER TRAIN PROBLEM
- Date Of Incident: 2012-08-08
- VIN: 1GCGG25V741
- Components: POWER TRAIN
- Summary: TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 2500. THE CONTACT STATED WHENEVER AT AN IDLE A LOUD METAL TO METAL NOISE WOULD EMIT CONTINUOUSLY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC ON TWO SEPARATE OCCASIONS WHERE THE CRACKED FLYWHEEL WAS REPLACED EACH TIME. THE MANUFACTURER WAS NOT NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 119,000.
STEERING PROBLEM
- Date Of Incident: 2013-06-08
- Fire: 1
- VIN: 1GAHG39U741
- Components: STEERING
- Summary: ON JUNE 08, 2013 MY HUSBAND HAD PARKED THE VAN ALONG SIDE THE ROAD - HE WAS OUT OF IT WORKING. THE VEHICLE WAS NOT RUNNING - WHEN A COWORKER NOTICED SMOKE COMING FROM THE VAN. THE COWORKER RAN OVER TO THE VAN AND SEEN THAT THE FIRE WAS IN THE STEERING COLUMN. WITHIN MINUTES THE ENTIRE VAN WAS ON FIRE. MY CONCERN IS THAT THIS VAN HAD BEEN HAVING ISSUES WITH SOMETHING SECURITY. ALL OF THE GAUGES WOULD SHUT DOWN AND IT WOULD DISPLAY "SECURITY " ON THE DASH. I PERSONALLY HAD CONTACTED OUR LOCAL CHEVY DEALER TO INQUIRE ABOUT THIS PROBLEM AND HOW TO TAKE CARE OF IT. THE LOCAL DEALER SUGGESTED A NEW KEY MADE AT THE DEALERSHIP USING THE VIN NUMBERS. THIS MADE NO DIFFERENCE AS IT HAPPENED AGAIN. THIS TIME MY HUSBAND WENT TO A DEALERSHIP IN NORWALK, OHIO INQUIRING ABOUT THE PROBLEM - THEY HAD NO IDEA WHAT THE SOLUTION WAS EITHER. MY CONCERN IS THAT THE DEALERSHIPS HAVE NO IDEA WHAT THE "SECURITY" IS OR HOW TO FIX IT......ALSO I AM WONDERING IF THIS "SECURITY" ISSUE IS THE REASON THAT I LOST MY VAN TO THE FIRE ON JUNE 08, 2013. I CONTACTED GM BUT THEY BLEW ME OFF SAYING I HAD OWNED THE VEHICLE TOO LONG TO GET ANY MONEY FOR MY LOSS. THESE VANS ARE DESIGNED TO CARRY LOTS OF PEOPLE AND IF MY FAMILY HAD BEEN IN THIS VEHICLE AT THE TIME OF THE FIRE THERE WOULD NOT HAVE BEEN ENOUGH TIME TO GET EVERYONE OUT SAFELY AND THAT WORRIES ME GREATLY. *TR
STRUCTURE PROBLEM
- Date Of Incident: 2012-12-01
- VIN: 1GBFG15T841
- Components: STRUCTURE
- Summary: TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS G1500. THE CONTACT STATED THAT THE DRIVER AND PASSENGER SIDE DOUBLE DOOR HINGES FAILED AND THE DOORS COULD NOT BE OPENED. THE DEALER ADVISED THAT THE DOOR HINGES NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 109,000 AND THE APPROXIMATE FAILURE MILEAGE WAS 110,00.
FUEL SYSTEM, GASOLINE PROBLEM
- Date Of Incident: 2013-04-24
- Components: FUEL SYSTEM, GASOLINE
- Summary: TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 3500. THE CONTACT STATED THAT THE FUEL TANK PIPE WAS SEVERELY RUSTED AND WAS LEAKING. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSIS. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE DEFECT. THE APPROXIMATE FAILURE MILEAGE WAS 39,000. THE VIN WAS UNAVAILABLE.
FUEL/PROPULSION SYSTEM PROBLEM
- Date Of Incident: 2012-08-20
- VIN: 1GAHG35U541
- Components: FUEL/PROPULSION SYSTEM
- Summary: TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS. THE CONTACT STATED THAT AFTER REFUELING, FUEL SPEW BACK OUT OF THE FILLER NECK. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO DID NOT OFFER ANY ASSISTANCE SINCE THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER: 12V388000 (FUEL SYSTEM, GASOLINE: STORAGE: TANK ASSEMBLY: FILLER PIPE AND CAP). THE FAILURE AND CURRENT MILEAGE WAS 114,000. UPDATED 10/16/12*LJ THE CONSUMER STATED THE FUEL FILLER NECK CORRODED UPDATED 10/19/2012 *JS
FUEL SYSTEM, GASOLINE PROBLEM
- Date Of Incident: 2011-07-24
- VIN: 1GAHG35U241
- Components: FUEL SYSTEM, GASOLINE
- Summary: GASOLINE AND GASOLINE VAPOR WAS ESCAPING FROM THE FUEL FILLER PIPE LEADING TO THE FUEL TANK ON A 2004 CHEVY EXPRESS VAN 3500 SERIES. THE FILER PIPE WAS RUSTED THROUGH. THERE WAS A SEAM ON THE PIPE WHERE THE RUST THROUGH OCCURRED. GASOLINE WAS DRIPPING FROM THIS HOLE DURING GASOLINE FILL UP AND VAPORS WERE ENTERING THE PASSENGER COMPARTMENT. WE HAD IT REPLACED BY A CERTIFIED MECHANIC BECAUSE IT WAS A POTENTIALLY EXPLOSIVE SITUATION, ACCORDING TO THE MECHANIC. THIS WAS REPORTED TO GM. THERE WAS NO RECALL ON THIS PART, SO GM REFUSED TO PAY FOR THE COST OF THE REPLACEMENT PART AND LABOR. THE REPLACEMENT PART IS NOW PLASTIC. SO GM MUST HAVE RECOGNIZED THE PROBLEM (BUT FAILED TO RECALL) AND CHANGED THE PIPE TO A RUST-PROOF MATERIAL. *JS
STEERING,SERVICE BRAKES PROBLEM
- Date Of Incident: 2012-04-02
- VIN: 1GBJG31U841
- Components: STEERING,SERVICE BRAKES
- Summary: VEHICLE HAS CONTINUED TO EVIDENCE PROBLEMS SIMILAR TO WHAT'S DESCRIBED BY NHTSA CAMPAIGN ID NO. 04V452000. POWER STEERING PUMP AND BELTS HAVE BEEN REPLACED AND GM DEALER PERFORMED HYDRO BOOST INSPECTION TEST AND IT PASSED; SAID NO FURTHER ACTION REQUIRED. BUS HAS AGAIN LOST POWER STEERING AND BRAKES TO CAUSE A DANGEROUS CONDITION. DEALER SAYS IT IS NOT A VEHICLE THAT RECALL APPLIES TO. *JS
2004 Chevrolet Express recalls
The National Highway Traffic Safety Administration (NHTSA) has issued 7 recalls for different components of the 2004 Chevrolet Express.
- Manufacturer: GENERAL MOTORS LLC
- Components: FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP
- Summary: General Motors (GM) is recalling certain model year 2003-2004 Chevrolet Express and GMC Savana vehicles, equipped with a left side cargo door, and originally sold or currently registered in Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin, and the District of Columbia. Water and road contaminants may become trapped in the protective conduit that covers the fuel filler pipe and may cause the pipe to corrode.
- Consequence: Significant corrosion may allow fuel to leak during refueling, and in the presence of an ignition source; there is an increased risk of fire.
- Remedy: GM will notify owners, and dealers will install a new fuel filler neck, free of charge. The safety recall began on October 1, 2012. Owners may contact the Chevrolet owner center at 1-866-694-6546 and GMC at 1-866-996-9463.
- Manufacturer: SABERSPORT
- Components: EXTERIOR LIGHTING
- Summary: SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
- Consequence: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
- Remedy: SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON MAY 11, 2009. OWNERS MAY CONTACT SABERSPORT AT 1-909-598-7589.
- Manufacturer: GENERAL MOTORS CORP.
- Components: SEAT BELTS
- Summary: ON CERTAIN FULL-SIZE PASSENGER, CARGO, OR CUTAWAY VANS, THE FRONT AND REAR SEAT BELT BUCKLES WILL NOT LATCH OR WILL NOT UNLATCH.
- Consequence: IN THE EVENT OF A CRASH, A SEAT OCCUPANT MAY NOT BE PROPERLY RESTRAINED INCREASING THE RISK OF PERSONAL INJURY.
- Remedy: DEALERS WILL INSPECT THE BUCKLES AND, IF FOUND TO BE INOPERATIVE, THE ENTIRE BUCKLE ASSEMBLY WOULD BE REPLACED. FOR BUCKLES FOUND TO BE OPERATIVE, DEALER WILL REPLACE ONLY THE UPPER BUCKLE COVER. THE RECALL WILL BE CONDUCTED IN PHASES. THE FIRST PHASE MAILING BEGAN DURING MARCH 2006. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438 OR GMC AT 1-866-996-9463.
- Manufacturer: GENERAL MOTORS CORP.
- Components: 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.
- 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.
- Manufacturer: GENERAL MOTORS CORP.
- Components: POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:COLUMN SHIFT
- Summary: CERTAIN VANS WERE BUILT WITH A TRANSMISSION SHIFT CABLE ASSEMBLY THAT MAY SEPARATE. IF THE CABLE ASSEMBLY SEPARATES, THE TRANSMISSION SHIFT LEVER POSITION AND THE TRANSMISSION INDICATOR MAY NO LONGER CORRELATE.
- Consequence: IF THIS WERE TO OCCUR, THE VEHICLE COULD MOVE IN A DIRECTION NOT ANTICIPATED BY THE DRIVER, WHICH COULD RESULT IN A VEHICLE CRASH.
- Remedy: DEALERS WILL INSPECT THE TRANSMISSION SHIFT CABLE ASSEMBLY, AND IF NECESSARY, REPLACE IT. THE RECALL BEGAN ON AUGUST 19, 2004. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438 OR GMC AT 1-866-996-9463.
- Manufacturer: GENERAL MOTORS CORP.
- Components: SEAT BELTS:FRONT:BUCKLE ASSEMBLY
- Summary: CERTAIN VANS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 209, "SEAT BELT ASSEMBLIES." THESE VEHICLES MAY HAVE BEEN PRODUCED WITH SEAT BELT BUCKLE ASSEMBLIES CONTAINING A LATCH WITH A BRITTLE CONDITION THAT MAY NOT WITHSTAND THE FORCE REQUIREMENTS OF THE STANDARD.
- Consequence: THE SAFETY BELT MAY NOT RESTRAIN THE OCCUPANT AS INTENDED DURING A CRASH, WHICH COULD RESULT IN INJURY TO THE OCCUPANT.
- Remedy: DEALERS WILL REPLACE THE SAFETY BELT BUCKLE. THE RECALL BEAGN MAY 7, 2004. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438 OR GMC AT 1-866-996-9463.
- Manufacturer: GENERAL MOTORS CORP.
- Components: 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.
- 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.
Negative 2004 Chevrolet Express car reviews
Positive 2004 Chevrolet Express car reviews
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I've been driving the new style Express since 1997 and I must say, it's been a reliable companion. The first one I drove was brand new and I drove it for 17 years. I then bought a used 2003 and it's still going strong. One of the best things about this van is the ample space it provides. I've moved my kids all over the place and it's never failed me. Of course, like any vehicle, it has needed repairs over the years, but nothing too major. It's a great van for road trips and it drives like a dream - it's like having a living room on wheels! Although I've never had the chance to try the AWD, I've compared it to many other vans and it still comes out on top. I had the 4 door v8 and it had all the power I needed.
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If you're looking for power, great looks, and tons of room without being lumped into the soccer mom mini van crowd, this is the van for you! But what about the poor gas mileage? Check out any dealer lot and see how many thousands of dollars you'll save over their mini van counterparts. Yes, enough to offset many years of 'mediocre' gas mileage.
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Hi there! I just wanted to share how much I love my van. It's been such a great help for transporting my dogs to and from competitive events and vet visits. The size is just perfect for my needs and it's incredibly easy to take the seats in and out depending on what I need it for. I've been so impressed with how reliable it's been - the only repair I've needed was for a water pump gasket.
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I love my van! It's so versatile and can handle any terrain, even in the snow. Living on an 800ft gravel drive that's plowed by our farm tractor has never been an issue for my trusty van. It comfortably fits six kids, two dogs, and two adults, making it perfect for family outings. The only downside is the cost of gas.
Additional sources
More sources of information about 2004 Chevrolet Express problems:
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Apr 3, 2019 ... Hello, my name is John and I have been reading about the common problems with these Chevy express vans with the spider fuel injection sytems ...
Other years of Chevrolet Express
Are you having problems with your 2004 Chevrolet Express?
Kenneth Lockman 2024-11-07
I purchased this vehicle with the intention of transporting my six children, but unfortunately, I experienced several issues due to poor GM quality. Despite being covered by the bumper-to-bumper warranty, I encountered several problems that were quite frustrating. For the price of over $30,000, I expected more than just a big 6.0L V8 engine. Unfortunately, the vehicle lacked rear cupholders and headrests, and the rear bench seats were uncomfortable for adults. Additionally, the fit and finish were poor, and plastic parts broke easily. Even with rear A/C, it struggled to keep cool on 90-degree days. The OEM tires needed replacing at less than 30K miles, and the vehicle has been recalled three times. I experienced several issues before reaching 36K miles, including a failed radio, broken plastic window latch, broken door switch, and broken door latch. The front bearings separated at 37K miles, and there was an A/C leak at 38K. The rotors also warped at 40K, and the window switch failed at 42K.
Keon McGlynn 2024-10-25
This car has had several issues since day one, including a check engine light, pulling to the right, warm air from the A/C, engine tapping, transmission slipping into reverse, loose window, peeling bowtie, and moisture in the blinker. Additionally, there have been multiple repairs on the right side sliding doors, tierod and gas pedal assembly replacements, a completely rebuilt differential, and issues with the glove box lock assembly and rear door windows leaking water. The rear jack cover also keeps falling off and the seat belt retainers have all broken off. The gas tank cap assembly and gas gauge have also required replacement. Despite these challenges, we have been able to identify and address the root cause of the current issue with the fuel and the check engine light. We are confident that we can continue to provide reliable transportation for our customers.
Glennie Larson 2024-08-15
While the engine and transmission of these vehicles are superior to those of Fords, the rest of the vehicle falls short. The old 1975-1992 Econoline has more room, feels better, drives better, handles better, and has a more solid body. The interior of the Express is uncomfortable and made of hard plastic that creaks and feels like it might break. The front seating is cramped and less roomy than Ford. The ride is not very smooth and can be a bit rough. The sliding door rattles and shakes when closed gently. All doors, controls, seats, and dash feel cheap compared to Ford. However, we understand that everyone has different preferences and priorities when it comes to choosing a vehicle.
Jarvis Schimmel 2024-05-14
Chevrolet needs to improve the assembly of this vehicle. There are several issues with the weather gaskets, grommets, and sealant on the door hinges and entry areas. The fuel fill door compartment is also prone to collecting road salt and sand. Although the ride is smooth and acceleration is good, there are driveline vibrations and resonance problems that need to be addressed. Despite these issues, the interior is the best that Chevrolet offers. However, the seats could be improved for a vehicle that lists for over $35,000.
Cory Mante 2024-04-05
One issue I have encountered with this vehicle is the lack of available aftermarket products such as bug shields or hood bras. Additionally, the body is constructed with thinner metal than what I would consider normal, especially when compared to my Dodge van. The way the plastic interior walls interlock is also disappointing, as some pieces just lay in place without any interlocking mechanism. Furthermore, the oil change light is not very useful to me as it only goes off at 7000 miles, while I prefer to change my oil every 3000 miles. Lastly, for shorter individuals, the step up into the vehicle can be difficult without holding onto the seat and pulling oneself in. Despite these issues, I still appreciate the vehicle for its other features.