Chevrolet G3500 2004 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 Chevrolet G3500 2004 problems
The 2004 Chevrolet Express 3500 is a popular choice for commercial vehicles, but like any other vehicle, it has its share of common problems. Here are some of the most frequently reported issues by owners:
- Safety Belt Buckle Failure: The safety belt buckle in the 2004 Chevrolet Express 3500 may not restrain the occupant during a crash, which could result in injury. The issue is caused by brittle seat belt buckle assemblies that do not meet the force requirements of the federal motor vehicle safety standard. The recall began on May 7, 2004, and affected 331 vehicles. Dealers will replace the safety belt buckle free of charge.
- Hydro-Boost Assembly Failure: The hydro-boost assembly in the 2004 Chevrolet Express 3500 may have a crack or fractured surface, which could cause hydraulic fluid to leak from the accumulator circuit of the booster assembly. This could lead to increased steering and braking effort, and a crash may occur without prior warning. The recall began in March 2005 and affected 155,465 vehicles. Dealers will test the hydro-boost assembly for functional operation of the two-function valve. If the hydro-boost assembly fails the test, dealers are to replace the assembly free of charge.
- Transmission Shift Cable Separation: The transmission shift cable assembly in the 2004 Chevrolet Express 3500 may separate, causing the transmission shift lever position and the transmission indicator to no longer correlate. If the cable assembly separates, the vehicle could move in a direction not anticipated by the driver, which could result in a vehicle crash. The recall began on August 19, 2004, and affected 1,792 vehicles. Dealers will inspect the transmission shift cable assembly and replace it if necessary, free of charge.
- Hydro-Boost Relief Valve Fracture: The hydro-boost relief valve in the 2004 Chevrolet Express 3500 may fracture, causing steering efforts to be slightly increased while braking or parking. Under certain driving conditions, a fractured seal may require a slight increase in applied brake pedal effort to achieve the same vehicle deceleration rate as prior to the seat fracture. The recall began on April 26, 2004, and affected 68,875 vehicles. Dealers are to replace the hydro-boost relief valve free of charge.
- Fuel Cap Issues: Some owners of the 2004 Chevrolet Express 3500 have reported difficulty finding a locking fuel cap for their RVs that are on a 2020 Chevrolet Express 3500 cutaway chassis with a 6L engine and 8 cylinders.
It is important to note that not all 2004 Chevrolet Express 3500 vehicles are affected by these issues, and owners should check their vehicle's Vehicle Identification Number (VIN) to see if their vehicle is affected by any recalls or safety notices. Owners can contact Chevrolet or GMC for more information on these issues and to schedule any necessary repairs.
Is Chevrolet Van reliable?
The Chevrolet Express 1500 Reliability Rating is 3.0 out of 5.0, which ranks it 9th out of 21 for commercial vans.
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.
Why is the speedometer not working on my Chevy Express van?
The most common reasons a Chevrolet Express 3500 speedometer isn't working are the vehicle speed sensor (VSS), a faulty speedometer, or an electrical issue.
What engine comes in a 2006 Chevy Express 3500?
Four engines are available. Light-duty G-Series vans have a 195-horsepower, 4.3-liter V-6 as the base engine. Three V-8s are offered: a 285-hp 4.8-liter, a 295-hp 5.3-liter and the 6.0-liter Vortec 6000 V-8 that generates 300 hp and 360 pounds-feet of torque.
Chevrolet G3500 2004 car problems categorized by type of issue
After analyzing all complaints sent to the NHTSA and researching popular Chevrolet G3500 problems, we found that the most common problems with these 2023 model year vehicles are:
- Steering problems
- Suspension problems
- Power train problems
The graph below shows statistics for all Chevrolet G3500 2004 vehicle components and the number of complaints received.
Chevrolet G3500 2004 complaints
The NHTSA has received 1 complaints about various vehicle components related to the Chevrolet G3500 2004.
STEERING,SUSPENSION,POWER TRAIN PROBLEM
- Date Of Incident: 2010-02-15
- VIN: 1GCHK33214F
- Components: STEERING,SUSPENSION,POWER TRAIN
- Summary: FRONT WHEEL BEARING/HUB FAILURE ON CHEVY SILVERADO HD 4WD DURAMAX PICKUPS: I AND SEVERAL FRIENDS OWNING THE SAME VEHICLES HAVE ALL EXPERIENCED FRONT WHEEL BEARING/HUB FAILURE AT BETWEEN 60,000 TO 80,000 MILES. THIS APPEARS TO BE A SAFETY ISSUE AND GM WILL NOT RECOGNIZE THIS KNOWN ISSUE. THIS ASSEMBLY IS NOT ENGINEERED PROPERLY AND CANNOT HOLD UP TO THE WEIGHT OF THE DIESEL AND 4WD COMPONENTS. THE SAME HUB ASSEMBLY IS USED IN GM GAS ENGINE POWERED HD TRUCKS AND THERE DOESN'T SEEM TO BE AN ISSUE. THERE IS ABSOLUTELY NO REASON FOR THESE TO EVER GO OUT. I AVERAGE ABOUT 13K MILES A YEAR, WELL BELOW THE AVERAGE NUMBER OF YEARLY DRIVEN MILES, AND THE DRIVER SIDE FAILED AT 70K AND PASSENGER SIDE AT 77K. THIS IS A SEALED REMOVE AND REPLACE UNIT THAT SEEMS TO BE POORLY ENGINEERED AND I FEEL THERE SHOULD BE A RECALL ISSUED. *TR
Additional sources
More sources of information about Chevrolet G3500 2004 problems:
2004 Chevrolet Express 3500 Q&A: Van Specs, Reviews & More
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Chevrolet Express 3500 Problems and Complaints - 22 Issues
Our list of 22 known complaints reported by owners can help you fix your Chevrolet Express 3500 ... Find the most common issues ... 2004 Chevrolet Express 3500 ...
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