2004 Chevrolet Express 2500 problems, complaints & recalls
Most-reported problem areas: Power Train (2) · Service Brakes, Hydraulic:antilock/Traction Control/Electronic Limited Slip (1) · Service Brakes, Hydraulic (1)
🧭 Reliability snapshot
Compared against other Chevrolet Express 2500 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 (94)
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 94 bulletins. Search all of them free at nhtsa.gov.
What owners report
2016-10-05 · Service Brakes · 115,000 mi“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 ca…”
2013-08-02 · Power Train · 119,000 mi“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 mileag…”
2012-02-06 · Engine And Engine Cooling · 15,500 mi“as i attempted to speed up in traffic, i heard a noise and the vehicle suddenly slowed down. i was able to get it off the highway on to a side road. once there, it would not start. on closer inspection, i saw that the belt had come apart and off the pulley's. i had the van towed to my home and subsequently, fixed/replaced the belt. since that time,…”
2010-06-14 · Power Train · 103,000 mi“mysterious coolant leak. reservoir is low and needs refilling often. mechanic has performed pressure test to no avail. no coolant on ground at any point. no visible signs of leak. this began right after 2nd cracked flywheel was replaced. at the same time a lifter knock began as well. 1st flywheel was replaced at 103k (3k outside of extended …”
2010-04-15 · Power Train:automatic Transmission“repeated cracked flywheel. original cracked just over 100k miles. replacement now cracked 40k miles later. *tr…”
2010-01-15 · Service Brakes, Hydraulic · 26,500 mi“i own a 2004 silverado 2500 hd with 26,500 miles on it. i had my truck serviced for speedometer that was not working and was told by karl chevy here in ankeny, ia that all of my rotors and brake pads needed to be replaced because of rust. gm ought to fix my brakes for free, they need to recall. i am 61 and have owned a few automobiles and have …”
2006-06-07 · Equipment · 21,000 mi“dt*: the contact stated the electrical module that controls the audio warning system is located in the original radio. the contact switched the radio and lost all of the audio warning systems. the dealer and manufacturer was alerted and determined the module was in the original radio and it should be put back in the vehicle. …”
2005-12-30 · Service Brakes, Hydraulic:antilock/Traction Control/Electronic Limited Slip · 💥 crash“during a sudden stop chevy 2500 express abs brakes pulled to the right or left. *ts the consumer stated the problem usually occurred during a panic stop. the consumer stated he had three separate accidents because of the defective brakes. *jb…”
Excerpts of consumer complaints filed with NHTSA, lightly truncated. They are owner statements, not verified findings.