The 2004 Chevrolet Express has 7 safety recalls and 21 owner complaints on file with NHTSA. The most-reported problem area is seat belts (3 complaints).
Recalls7safety recalls
Complaints21filed by owners
Crashes · fires1 · 2reported in complaints
Injuries · deaths0 · 0reported in complaints
Safety recalls
Fuel system, gasoline › Storage › Tank assembly › Filler pipe and cap
NHTSA recall 12V388000 · Aug 8, 2012 · 9,389 vehicles · opened after NHTSA action (ODI)
Problem: 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 protective conduit that covers the fuel filler pipe and may cause the pipe to corrode.
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.
Exterior lighting
NHTSA recall 09E012000 · Apr 7, 2009 · 16,270 vehicles · opened after NHTSA action (OVSC)
Problem: SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
Risk: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
Fix: SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON MAY 11, 2009. OWNERS MAY CONTACT SABERSPORT AT 1-909-598-7589.
Seat belts
NHTSA recall 05V558000 · Dec 19, 2005 · 425,593 vehicles
Problem: ON CERTAIN FULL-SIZE PASSENGER, CARGO, OR CUTAWAY VANS, THE FRONT AND REAR SEAT BELT BUCKLES WILL NOT LATCH OR WILL NOT UNLATCH.
Risk: IN THE EVENT OF A CRASH, A SEAT OCCUPANT MAY NOT BE PROPERLY RESTRAINED INCREASING THE RISK OF PERSONAL INJURY.
Fix: DEALERS WILL INSPECT THE BUCKLES AND, IF FOUND TO BE INOPERATIVE, THE ENTIRE BUCKLE ASSEMBLY WOULD BE REPLACED. FOR BUCKLES FOUND TO BE OPERATIVE, DEALER WILL REPLACE ONLY THE UPPER BUCKLE COVER. THE RECALL WILL BE CONDUCTED IN PHASES. THE FIRST PHASE MAILING BEGAN DURING MARCH 2006. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438 OR GMC AT 1-866-996-9463.
Service brakes, hydraulic
NHTSA recall 05V043000 · Feb 8, 2005 · 77,411 vehicles
Problem: CERTAIN TRUCKS, SPORT UTILITY VEHICLES, AND VANS EQUIPPED WITH BOSCH HYDRO-BOOST BRAKE ASSEMBLIES, THE HYDRAULIC BRAKE BOOSTER PRESSURE ACCUMULATOR MAY CRACK AND SEPARATE FROM THE HYDRO-BOOST ASSEMBLY DURING NORMAL OPERATING CONDITIONS.
Risk: IF A SEPARATION OCCURRED AND THE HOOD OF THE VEHICLE WERE OPEN, FRAGMENTS FROM THE ACCUMULATOR COULD CAUSE INJURY TO PEOPLE IN THE IMMEDIATE AREA. THE PRESENCE OF THIS CRACK OR FRACTURED SURFACE COULD ALLOW THE HYDRAULIC FLUID TO LEAK FROM THE ACCUMULATOR CIRCUIT OF THE BOOSTER ASSEMBLY. THE LOSS OF FLUID WOULD CAUSE INCREASED STEERING AND BRAKING EFFORT AND A CRASH MAY OCCUR WITHOUT PRIOR WARNING.
Fix: DEALERS WILL TEST THE HYDRO-BOOST ASSEMBLY FOR FUNCTIONAL OPERATION OF THE TWO-FUNCTION VALVE. IF THE HYDRO-BOOST ASSEMBLY FAILS THE TEST, DEALERS WILL REPLACE THE ASSEMBLY FREE OF CHARGE. THE RECALL BEGAN ON MARCH 23, 2005. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438, GMC TRUCKS AT 1-866-996-9463 AND HUMMER AT 1-800-732-5493.
Power train › Automatic transmission › Lever and linkage › Column shift
Problem: CERTAIN VANS WERE BUILT WITH A TRANSMISSION SHIFT CABLE ASSEMBLY THAT MAY SEPARATE. IF THE CABLE ASSEMBLY SEPARATES, THE TRANSMISSION SHIFT LEVER POSITION AND THE TRANSMISSION INDICATOR MAY NO LONGER CORRELATE.
Risk: IF THIS WERE TO OCCUR, THE VEHICLE COULD MOVE IN A DIRECTION NOT ANTICIPATED BY THE DRIVER, WHICH COULD RESULT IN A VEHICLE CRASH.
Fix: DEALERS WILL INSPECT THE TRANSMISSION SHIFT CABLE ASSEMBLY, AND IF NECESSARY, REPLACE IT. THE RECALL BEGAN ON AUGUST 19, 2004. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438 OR GMC AT 1-866-996-9463.
Problem: CERTAIN VANS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 209, "SEAT BELT ASSEMBLIES." THESE VEHICLES MAY HAVE BEEN PRODUCED WITH SEAT BELT BUCKLE ASSEMBLIES CONTAINING A LATCH WITH A BRITTLE CONDITION THAT MAY NOT WITHSTAND THE FORCE REQUIREMENTS OF THE STANDARD.
Risk: THE SAFETY BELT MAY NOT RESTRAIN THE OCCUPANT AS INTENDED DURING A CRASH, WHICH COULD RESULT IN INJURY TO THE OCCUPANT.
Fix: DEALERS WILL REPLACE THE SAFETY BELT BUCKLE. THE RECALL BEAGN MAY 7, 2004. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438 OR GMC AT 1-866-996-9463.
Service brakes, hydraulic
NHTSA recall 04V045000 · Feb 4, 2004 · 68,875 vehicles
Problem: CERTAIN SPORT UTILITY VEHICLES, PICKUP TRUCKS, AND PASSENGER VANS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 135, ?PASSENGER CAR BRAKE SYSTEMS.? SOME OF THESE VEHICLES WERE PRODUCED WITH AN OUT-OF-SPECIFICATION BRAKE HYDRO-BOOST HOUSING RELIEF VALVE BORE.
Risk: CONSEQUENTLY, THE VALVE O-RING SEAL MAY FRACTURE. STEERING EFFORTS MAY BE SLIGHTLY INCREASED WHILE BRAKING OR PARKING. UNDER CERTAIN DRIVING CONDITIONS, A FRACTURED SEAL MAY REQUIRE A SLIGHT INCREASE IN THE APPLIED BRAKE PEDAL EFFORT TO ACHIEVE THE SAME VEHICLE DECELERATION RATE AS PRIOR TO THE SEAT FRACTURE.
Fix: DEALERS ARE TO REPLACE THE HYDRO-BOOST RELIEF VALVE. THE RECALL BEGAN ON JUNE 18, 2004. OWNERS SHOULD CONTACT CADILLAC AT 1-866-982-2339; CHEVROLET AT 1-800-630-2438; GMC AT 1-866-996-9463; OR HUMMER AT 1-866-486-6376.
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
Overall
Not Rated
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.
Fuel economy
Express 1500/2500 2WD
15mpg combined
City / highway
13 / 18 mpg
Fuel
Regular Gasoline
4.3 L · 6 cyl · Automatic 4-spd · Rear-Wheel Drive · about $4,450/year to fuel
Express 1500/2500 2WD
15mpg combined
City / highway
14 / 18 mpg
Fuel
Regular Gasoline
5.3 L · 8 cyl · Automatic 4-spd · Rear-Wheel Drive · about $4,450/year to fuel
Express Cargo (Bi-fuel) Bifuel (CNG)
12mpg combined
City / highway
11 / 15 mpg
Fuel
Regular Gasoline
6 L · 8 cyl · Automatic 4-spd · Rear-Wheel Drive · about $5,600/year to fuel
Express Passenger (Bi-fuel) Bifuel (CNG)
12mpg combined
City / highway
11 / 15 mpg
Fuel
Regular Gasoline
6 L · 8 cyl · Automatic 4-spd · Rear-Wheel Drive · about $5,600/year to fuel
Express Cargo (dedicated CNG) CNG
12mpg combined
City / highway
11 / 15 mpg
Fuel
Natural Gas
6 L · 8 cyl · Automatic 4-spd · Rear-Wheel Drive · about $3,850/year to fuel
Express Passenger (dedicated CNG) CNG
12mpg combined
City / highway
11 / 15 mpg
Fuel
Natural Gas
6 L · 8 cyl · Automatic 4-spd · Rear-Wheel Drive · about $3,850/year to fuel
EPA estimates from fueleconomy.gov for each engine and transmission sold. Annual cost is the EPA's estimate for 15,000 miles a year at its current fuel and electricity price assumptions. Your results will vary.
What owners report
Problem area
Complaints
Crashes
Fires
Injuries
Typical mileage*
Seat belts Front › Buckle assembly
3
0
0
0
—
Service brakes, hydraulic
3
0
0
0
37,000 mi
Service brakes
3
0
0
0
—
Steering Linkages › Knuckle › Spindle › Arm
2
0
0
0
—
Fuel system, gasoline Delivery › Fuel pump
2
0
0
0
—
Electrical system Alternator/generator/regulator; 12v/24v/48v battery
2
0
0
0
—
Structure Body
2
0
1
0
—
Fuel/propulsion system
2
0
0
0
—
Engine and engine cooling Engine
1
0
0
0
—
Air bags
1
1
0
0
—
Parking brake
1
0
0
0
—
Power train Automatic transmission › Lever and linkage › Column shift
1
0
0
0
—
*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.
Recent owner complaints
Dec 4, 2021Fuel/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.
Nov 12, 2021Suspension 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 not repair this vehicle for use to drive on roads. I am requesting a local representative to help evaluate if this vehicle is safe to travel on Oklahoma roads.
Nov 8, 2016 · 148,000 milesFuel/propulsion system 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
Sep 11, 2016 · 33,000 milesVisibility/wiper 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. UPDATED 01/31/17*LJ CONSUMER STATED DRIVERS SIDE REAR SEAT LOWER WINDOW BROKE. GLUE CAME OFF MANUFACTURED WINDOW MADE BY C.R. LAURENCE CO, INC. WINDOW WAS REPLACED 11/08/16. UPDATED 6/22/18*JB
Sep 3, 2016 · 150,000 miles · fireStructure › Body 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.
Aug 9, 2016 · 146,000 milesSeat belts TWO REAR BUCKET SEAT BELT CABLES HAVE BROKEN WITHOUT IMPACT.
Jun 6, 2014 · 205,765 miles · fireEngine ENGINE EXHAUST MANIFOLD BROKEN BOLTS,HAS 3 AT THIS POINT AND TIME. THIS CAUSES THE EXHAUST TO LEAK INTO DRIVERS COMPARTMENT. *TR
Aug 15, 2012 · 110,000 milesService brakes 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 PRIVATE MECHANIC WHERE IT WAS DIAGNOSED THAT THE BRAKE SENSORS AND THE ABS MAIN CONTROL SYSTEM NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS REPAIRED BUT THE FAILURE RECURRED. THE FAILURE MILEAGE WAS 110,000 AND THE CURRENT MILEAGE WAS UNKNOWN.
Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.
NHTSA defect investigations
EA04012 · opened Apr 30, 2004 · closed Feb 28, 2005 · led to recall 05V005000HYDRAULIC PUMP FAILRES GM IS CONDUCTING A RECALL ON ALL SUBJECT VEHICLES BUILD BETWEEN MAY 1999 AND OCTOBER 14, 1999.SIGNIFICANT CHANGES WERE INCORPORATED INTO PRODUCTION IN EARLY OCTOBER 1999, AND VEHICLES BUILT AFTER THAT DATE HAVE LOWER WARRANTY FAILURE RATES.THE COMPLAINT AND WARRANTY DATA APPEAR TO SUPPORT THE EFFECTIVENESS OF THESE CHANGES. GM MADE ADDITIONAL CHANGES IN NOVEMBER 1999, FEBRUARY 2000, MAY 2001, AND FEBRUARY 2004.ODI WILL CONTINUE TO MONITOR THIS PROBLEM AND WILL TAKE FURTHER ACTION, IF WARRANTED, IN THE FUTURE.FOR FURTHER TECHNICAL DETAILS SEE THE ATTACHED ENGINEERING ANALYSIS REPORT.