Model year record
2004 Chevrolet Express 3500 recalls & problems
The 2004 Chevrolet Express 3500 has no safety recalls on file with NHTSA, and 16 owner complaints. The most-reported problem area is steering (4 complaints).
Safety recalls
No safety recalls have been filed for the 2004 Chevrolet Express 3500.
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.
Crash test ratings
2004 Chevrolet Express Van 3500 15 Passenger Van
| Frontal crash | Not Rated |
|---|---|
| Side crash | Not Rated |
| Rollover | Not Rated |
NHTSA 5-Star Safety Ratings (New Car Assessment Program). Ratings are comparable only between vehicles of similar size and weight, and ratings from 2011 on use tougher tests than earlier years. Photos: NHTSA.
What owners report
| Problem area | Complaints | Typical mileage* |
|---|---|---|
| SteeringLinkages › Arm › Idler and attachment | 4 | 60,000 mi |
| Service brakes, hydraulicFoundation components › Disc › Rotor | 3 | 50,000 mi |
| StructureBody › Door › Hinge and attachments; Body › Door | 3 | — |
| Fuel system, gasolineStorage › Tank assembly › Filler pipe and cap | 3 | 104,000 mi |
| Service brakes | 2 | — |
| Electronic stability control (esc) | 1 | — |
| Fuel/propulsion system | 1 | — |
| Tires | 1 | — |
*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.
Recent owner complaints
- Service brakes
2004 CHEVROLET EXPRESS COLLINS SCHOOL BUS WHILE DRIVING AT 15 MPH ON AN INCLINED RURAL COUNTRY ROAD ATTEMPTING TO BRAKE NOTICED PEDAL EXTENDED TO THE FLOOR AND WAS STOPPED BY FURTHER DOWN SHIFTING AND APPLYING EMERGENCY BRAKE. INFORMED BY REPAIR SHOP THE RIGHT FRONT HYDRAULIC LINE RUBBED THROUGH THE METAL BRAKE LINE CAUSING THE FAILURE. FAILURE MILEAGE 43,997.
- Tires
TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 3500 EQUIPPED WITH TOYO OPEN COUNTRY H/T TUFF DUTY TIRES, SIZE: LT245/75/R16 TIRES. WHILE DRIVING 65 MPH, THE CONTACT HEARD A LOUD NOISE AND THE REAR DRIVER SIDE TIRE BLEW OUT. THE VEHICLE WAS TOWED TO A DEALER WHO DIAGNOSED THAT ALL FOUR TIRES HAD CRACKS AND NEEDED TO BE REPLACED. IN ADDITION, MULTIPLE PARTS NEEDED TO BE REPLACED. THE TIRES WERE REPLACED, BUT THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE FAILURE MILEAGE WAS 120,187 AND THE TIRE FAILURE MILEAGE WAS 25,982.
- Structure › Body › Door › Hinge and attachments
TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 3500. THE CONTACT STATED THAT THE PASSENGER AND DRIVER SIDE DOOR HINGES WERE FRACTURED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 25,000.
- Service brakes
TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 3500. THE CONTACT STATED WHILE DRIVING DOWN A MOUNTAIN ROAD APPROXIMATELY 45 MPH THE BRAKE PEDAL WAS DEPRESSED AND THE VEHICLE BEGAN TO VIBRATE EXCESSIVELY AND THE BRAKE DISCS OVERHEATED. THE FAILURE WAS NOT DIAGNOSED NOR WAS THE VEHICLE REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE DEFECT. THE APPROXIMATE FAILURE MILEAGE WAS 128,000. UPDATED 08/11/14*LJ UPDATED 08/18/2014 *JS
- Fuel/propulsion system
TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 3500. THE CONTACT STATED THE FUEL FILLER NECK TUBE WAS CORRODED, CAUSING FUEL TO LEAK WHEN REFUELING THE VEHICLE. THE CONTACT REFERENCED NHTSA CAMPAIGN NUMBER: 12V388000 (FUEL SYSTEM, GASOLINE) BUT WAS ADVISED BY THE MANUFACTURER THAT THE VIN WAS NOT INCLUDED IN THE RECALL. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 130,000.
- SteeringFire
ON JUNE 08, 2013 MY HUSBAND HAD PARKED THE VAN ALONG SIDE THE ROAD - HE WAS OUT OF IT WORKING. THE VEHICLE WAS NOT RUNNING - WHEN A COWORKER NOTICED SMOKE COMING FROM THE VAN. THE COWORKER RAN OVER TO THE VAN AND SEEN THAT THE FIRE WAS IN THE STEERING COLUMN. WITHIN MINUTES THE ENTIRE VAN WAS ON FIRE. MY CONCERN IS THAT THIS VAN HAD BEEN HAVING ISSUES WITH SOMETHING SECURITY. ALL OF THE GAUGES WOULD SHUT DOWN AND IT WOULD DISPLAY "SECURITY " ON THE DASH. I PERSONALLY HAD CONTACTED OUR LOCAL CHEVY DEALER TO INQUIRE ABOUT THIS PROBLEM AND HOW TO TAKE CARE OF IT. THE LOCAL DEALER SUGGESTED A NEW KEY MADE AT THE DEALERSHIP USING THE VIN NUMBERS. THIS MADE NO DIFFERENCE AS IT HAPPENED AGAIN.…
- Fuel system, gasoline
TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 3500. THE CONTACT STATED THAT THE FUEL TANK PIPE WAS SEVERELY RUSTED AND WAS LEAKING. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSIS. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE DEFECT. THE APPROXIMATE FAILURE MILEAGE WAS 39,000. THE VIN WAS UNAVAILABLE.
- Fuel system, gasoline › Storage › Tank assembly › Filler pipe and cap
GASOLINE AND GASOLINE VAPOR WAS ESCAPING FROM THE FUEL FILLER PIPE LEADING TO THE FUEL TANK ON A 2004 CHEVY EXPRESS VAN 3500 SERIES. THE FILER PIPE WAS RUSTED THROUGH. THERE WAS A SEAM ON THE PIPE WHERE THE RUST THROUGH OCCURRED. GASOLINE WAS DRIPPING FROM THIS HOLE DURING GASOLINE FILL UP AND VAPORS WERE ENTERING THE PASSENGER COMPARTMENT. WE HAD IT REPLACED BY A CERTIFIED MECHANIC BECAUSE IT WAS A POTENTIALLY EXPLOSIVE SITUATION, ACCORDING TO THE MECHANIC. THIS WAS REPORTED TO GM. THERE WAS NO RECALL ON THIS PART, SO GM REFUSED TO PAY FOR THE COST OF THE REPLACEMENT PART AND LABOR. THE REPLACEMENT PART IS NOW PLASTIC. SO GM MUST HAVE RECOGNIZED THE PROBLEM (BUT FAILED TO RECALL) AND…
Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.