2004 Chevrolet Express: problems, recalls and reliability
7 recalls and 21 owner complaints on record; most reports concern service brakes, hydraulic.
Data updated weekly · latest recall Aug 2012
All counts are reports filed with NHTSA in the United States - US market only, not worldwide totals.
Common problems
Computed from 21 owner complaints filed with NHTSA for this exact model year.
“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.”Owner report · Fuel/Propulsion System · Dec 2021
“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.”Owner report · Suspension · Nov 2021
“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”Owner report · Fuel/Propulsion System · Nov 2016
Show 7 more owner reports
“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”Owner report · Visibility/Wiper · Sep 2016
“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.”Owner report · Structure · Sep 2016
“Engine exhaust manifold broken bolts,has 3 at this point and time. This causes the exhaust to leak into drivers compartment. *tr”Owner report · Engine · Jun 2014
“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.”Owner report · Power Train · Jan 2013
“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.”Owner report · Structure · Dec 2012
“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.”Owner report · Service Brakes · Aug 2012
“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”Owner report · Steering · Apr 2012
When filing, owners marked a crash in 1 of these complaints and injuries in 0 - self-reported to NHTSA, not verified accident statistics.
Recalls - 7 campaigns
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.
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.
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.
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.
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.
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.
ON CERTAIN FULL-SIZE PASSENGER, CARGO, OR CUTAWAY VANS, THE FRONT AND REAR SEAT BELT BUCKLES WILL NOT LATCH OR WILL NOT UNLATCH.
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.
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.
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.
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.
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.
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.
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.
Trouble codes owners mention
OBD-II codes that appear in NHTSA complaints about this car.
How other years compare
Check your exact Express by VIN
Recalls and equipment differ between individual vehicles. Decode your VIN to see what applies to yours.
Open VIN decoderFrequently asked questions
Is the 2004 Chevrolet Express reliable?
NHTSA has 21 owner complaints and 7 recall campaigns on record for the 2004 Chevrolet Express. The most complained-about area is service brakes, hydraulic.
Does the 2004 Chevrolet Express have open recalls?
7 recall campaigns have been issued, the latest concerning power train:automatic transmission:lever and linkage:column shift. Check your specific vehicle by VIN - recall repairs are free at franchised dealers.
Source: NHTSA recall campaigns and owner complaints (public domain). Counts reflect reports on file and are not a defect rate.