Model year record

2004 Chevrolet Express 2500 recalls & problems

The 2004 Chevrolet Express 2500 has 2 safety recalls and 8 owner complaints on file with NHTSA. The most-reported problem area is power train (3 complaints).

Recalls2safety recalls

Complaints8filed by owners

Crashes · fires1 · 0reported in complaints

Injuries · deaths0 · 0reported in complaints

Safety recalls

Fuel system, gasolineMay 19, 2006

Fuel system, gasoline

Recall 06E04300088,303 vehicles

Problem: CERTAIN REPLACEMENT FUEL FILTERS, FRAM BRAND NAME P/N G3727, WITH DATE CODES X52911 THROUGH X60801 SEQUENTIALLY OR X600141 AND A MEXICO COUNTRY OR ORIGIN MARKING ON THE FUEL FILTER HOUSING MANUFACTURED FROM OCTOBER 18, 2005, THROUGH MARCH 21, 2006, SOLD FOR USE ON THE VEHICLES LISTED ABOVE AND ON CERTAIN SCHOOL BUSES. (TO SEE THE SCHOOL BUS ENGINE SIZES, CLICK ON "DOCUMENT SEARCH" AND THEN "BUS APPLICATIONS"). THE CONNECTOR ON THE FUEL FILTER WAS NOT MANUFACTURED TO HONEYWELL'S SPECIFICATION. AS A RESULT, THE O-RING MAY NOT SEAT CORRECTLY ON THE FUEL LINE.
Risk: THIS CONDITION MAY CAUSE AN INADEQUATE SEAL AT THE CONNECTION, POTENTIALLY LEADING TO A FUEL LEAK. IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.
Fix: HONEYWELL WILL NOTIFY OWNERS AND REPLACE THE FUEL FILTERS FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 18, 2006. OWNERS MAY CONTACT FRAM CUSTOMER SERVICE AT 1-800-890-2075 (OPTION 1).

Exterior lightingDec 13, 2005

Exterior lighting

Recall 05V5590002 vehicles

Problem: CERTAIN CONVERSION VANS BUILT ON GMC/CHEVROLET CHASSIS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES AND ASSOCIATED EQUIPMENT." THE HOUSING LENS OF THE CENTER HIGH MOUNTED STOP LAMP DOES NOT ALLOW ENOUGH LIGHT TO EMIT FROM THE LAMP.
Risk: FOLLOWING VEHICLES MAY NOT BE FULLY INFORMED OF VEHICLE BRAKING. REAR-END CRASHES AND INJURY TO OCCUPANTS MAY OCCUR.
Fix: QUALITY COACHES IS WORKING WITH AUDIOVOX TO REPLACE THE CENTER HIGH-MOUNTED BRAKE LAMP ASSEMBLY. OWNERS MAY CONTACT QUALITY COACHES AT 1-800-373-6357 OR ASA AT 1-800-274-1886.

Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.

What owners report

Problem area	Complaints	Crashes	Typical mileage*
Power trainAutomatic transmission	3	0	—
Service brakes, hydraulicAntilock/traction control/electronic limited slip	2	1	—
Engine and engine cooling	2	0	—
Equipment	1	0	—
Electrical systemInstrument cluster/panel	1	0	—
Service brakes	1	0	—

*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.

Recent owner complaints

Service brakes
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 CAME TO A COMPLETE STOP. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBERS: 05V043000 (SERVICE BRAKES, HYDRAULIC) AND 04V045000 (SERVICE BRAKES, HYDRAULIC). THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 115,000.
Apr 7, 2014 · 115,000 miles
Power train
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 MILEAGE WAS 119,000.
Aug 8, 2012 · 119,000 miles
Engine and engine cooling
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, I BEGAN TO HEAR A LOW KNOCKING, MORE SO WHEN I TURNED ON THE AIR CONDITIONING. WHEN IT BECAME LOUDER ON ALL GEARS AND WHILE PARKED, I TOOK IT TO HOLLER DRIVERS MART, IN WINTER PARK, FL. ON 01/19/2012, I WAS TOLD THAT THE FLYWHEEL HAD SHEARED AROUND THE AREA WHERE IT WAS BOLTED ONTO THE TRANSMISSION AND CONNECTED TO THE ENGINE. IT ALSO HAD…
May 26, 2010 · 15,500 miles
Engine and engine cooling
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 WARRANTY). 2ND FLYWHEEL REPLACED AT 143K. VAN IS KEPT IN MINT CONDITION, OIL CHANGED EVERY 3K W/O FAIL. VEHICLE SEEMS TO BE IN OTHERWISE TERRIFIC CONDITION. 1ST AND ONLY OWNER. DATE REFERRED TO IS DATE OF 2ND FLYWHEEL CRACK. *TR
May 20, 2010 · 103,000 miles
Power train › Automatic transmission
REPEATED CRACKED FLYWHEEL. ORIGINAL CRACKED JUST OVER 100K MILES. REPLACEMENT NOW CRACKED 40K MILES LATER. *TR
Apr 15, 2010
Service brakes, hydraulic
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 NEVER HAD TO REPLACE ROTORS WITH SUCH LOW MILEAGE. THE MAJORITY OF MILES ARE HIGHWAY. I HAVE BEEN IN A RIDESHARE POOL USING A METRO VAN PROVIDED TO OUR POOL FOR THE LAST FOUR YEARS AS THE MAIN DRIVER. *TR
Jan 9, 2010 · 26,500 miles
Equipment
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.
Jun 7, 2006 · 21,000 miles
Service brakes, hydraulic › Antilock/traction control/electronic limited slipCrash
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
Jan 1, 1901

Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.