2004 Chevrolet Express 1500 problems, complaints & recalls
Most-reported problem areas: Fuel/Propulsion System (3) · Service Brakes, Hydraulic (2) · Visibility:windshield (1)
🧭 Reliability snapshot
Compared against other Chevrolet Express 1500 model years — complaint volume vs the model's median year, recalls and severity. How we score →
Safety recalls (0)
No recalls on record for this model year (campaigns announced since 2010).
Service bulletins (90)
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.
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.
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.
Unknown Or Other 2024-09-06 · PIT3271P · Service Bulletin/Repair Instructions
this preliminary information communication provides information to the technician about changing the tire and wheel size on vehicles. general motors will only support a tire calibration for tires that have been sized, tested and designed for the vehicle in question and its applications. technician s
Electrical System 2024-08-26 · General Communication · Service Campaign
vehicle wide programming (vwp) is a new process to update software on gm vehicles. it provides the ability via a single selection within techline connect to first identify which modules need updating and then proceed to updating affected modules (with some exceptions). the updating of modules is com
Power Train 2024-07-24 · 24-NA-141 · Service Bulletin/Repair Instructions
gm is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. the damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. this bulletin advises the dealers to be more careful not to damage the transmissions durin
Showing the 6 most recent of 90 bulletins. Search all of them free at nhtsa.gov.
What owners report
2019-01-20 · Fuel/Propulsion System · 33,000 mi“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 …”
2016-01-31 · Fuel/Propulsion System · 160,000 mi“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.…”
2015-05-29 · Structure:body · 250,000 mi · 💥 crash“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 …”
2012-08-22 · Fuel/Propulsion System · 114,000 mi“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).…”
2011-05-17 · Tires“we purchased a complete set of general grabber hts 235/75r16 for our chevy express van at dunn tire on 11/15/08. they were supposed to have a 60k warranty. we went in for the required rotations and noted that the tread didn't seem to be wearing well. at the 20k mile rotation in january of 2011, dunn tire acknowledged that the tires were not perf…”
2009-03-30 · Service Brakes, Hydraulic · 35,000 mi“abs engages at slow speed, at tail end of braking, even on dry surfaces. this has been going on for at least eight months. started sometime in early summer/late spring 2008. *tr…”
2009-03-19 · Air Bags · 91,048 mi“the passenger side airbag employed when the vehicle was parked inside the shop. the vehicle is available for inspection at stanley chevrolet celina tx 972-382-3000 contact gary werner service manager. the vehicle owner is rick dietel of amersol inc. 214-503-9977. *tr…”
2008-09-24 · Visibility · 120,000 mi“the windshield wipers will not turn off. *tr…”
2007-12-26 · Electrical System:wiring:fuses And Circuit Breakers · 166,000 mi · 🔥 fire“tl*the contact owns a 2004 chevrolet express 1500. the vehicle caught fire inside the fuse box after being parked for four days. the fire caused damage to the fuse box. as of december 26, 2007, the dealer had not inspected the vehicle. the purchase date was unknown. the current and failure mileages were 166,000. …”
2006-07-31 · Service Brakes, Hydraulic:foundation Components:master Cylinder · 21,719 mi“2004 chevrolet express g-van engine overheated causing smoke to come from driver cabinet and engine shut off. *kb the consumer experienced the problem on 4 separate occasions. the brake master cylinder was replaced. *jb…”
Excerpts of consumer complaints filed with NHTSA, lightly truncated. They are owner statements, not verified findings.