2004 Chevrolet Express problems, complaints & recalls
Most-reported problem areas: Service Brakes, Hydraulic (3) · Structure:body (2) · Seat Belts (2)
🧭 Reliability snapshot
Compared against other Chevrolet Express model years — complaint volume vs the model's median year, recalls and severity. How we score →
Safety recalls (1)
Fuel System, Gasoline:storage:tank Assembly:filler Pipe And Cap 2012-08-08 · campaign 12V388000 · 9,389 vehicles
Defect: 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 protecti
Risk: Significant corrosion may allow fuel to leak during refueling, and in the presence of an ignition source; there is an increased risk of fire.
Fix: 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.
Service bulletins (591)
Technical service bulletins are repair instructions manufacturers send dealers for known issues. Unlike recalls, the fix is not automatically free — but naming the bulletin at the service desk can save diagnosis time and support goodwill repairs.
Unknown Or Other 2025-07-18 · PIP5601C · Service Bulletin/Repair Instructions
this pi communicates the requirement to provide a pico file to receive diagnostic assistance from tac.
Unknown Or Other 2025-03-28 · 23-NA-001 · Service Bulletin/Repair Instructions
this service bulletin provides information for dealers/technicians on onstar module 2g sunset information.
Unknown Or Other 2025-02-20 · PIP5358D · Service Bulletin/Repair Instructions
this preliminary information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. technician should get record a sound clip or take a video of the noise for assessment by engineering. technician will need to
Engine 2024-12-18 · 03-06-01-023I · Service Bulletin/Repair Instructions
this service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.
Electrical System 2024-10-25 · PIP4723J · Service Bulletin/Repair Instructions
this preliminary information communicates to the dealer the process for downloading or updating operating software for the tire pressure monitor, active fuel injector tester, multi media tester, pico scope, gr8 starting/charging tester and vehicle data recorder tools, giving website address and ste
Engine 2024-10-07 · 03-06-01-023H · Service Bulletin/Repair Instructions
this service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.
Showing the 6 most recent of 591 bulletins. Search all of them free at nhtsa.gov.
What owners report
2022-03-01 · Fuel/Propulsion System“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.…”
2021-12-30 · Suspension“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 no…”
2016-11-09 · Fuel/Propulsion System · 148,000 mi“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…”
2016-10-17 · Visibility/Wiper · 33,000 mi“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. …”
2016-09-08 · Structure:body · 150,000 mi · 🔥 fire“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. …”
2016-08-09 · Seat Belts · 146,000 mi“two rear bucket seat belt cables have broken without impact.…”
2014-06-06 · Engine · 205,765 mi · 🔥 fire“engine exhaust manifold broken bolts,has 3 at this point and time. this causes the exhaust to leak into drivers compartment. *tr…”
2014-05-29 · Service Brakes · 110,000 mi“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…”
2014-05-29 · Power Train:automatic Transmission:lever And Linkage:column Shift · 120,000 mi“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 ve…”
2013-05-07 · Structure:body · 109,000 mi“ 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…”
Excerpts of consumer complaints filed with NHTSA, lightly truncated. They are owner statements, not verified findings.