Problem: General Motors, LLC (GM) is recalling certain 2003-2023 Chevrolet Express Cutaway and GMC Savana Cutaway incomplete vehicles equipped with wiring for an optional rear heating, ventilation, and air-conditioning (HVAC) system. When the HVAC blower motor circuit is left unused with exposed connectors and wiring, the circuit can corrode and overheat.
Risk: An overheated electrical circuit increases the risk of a fire.
Fix: Dealers will properly seal the rear HVAC blower motor circuits at the left side B-pillar, free of charge. Owner notification letters were mailed May 2, 2023. Owners may contact Chevrolet customer service at 1-800-222-1020 or GMC customer service at 1-800-462-8782. GMC's number for this recall is N222386050.
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.
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 GMC Savana 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
Savana 15/25 2WD Conversion (cargo)
15mpg combined
City / highway
13 / 17 mpg
Fuel
Regular Gasoline
4.3 L · 6 cyl · Automatic 4-spd · Rear-Wheel Drive · about $4,450/year to fuel
Savana 15/25 2WD Conversion (cargo)
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
Savana 1500/2500 2WD (cargo)
15mpg combined
City / highway
14 / 18 mpg
Fuel
Regular Gasoline
4.3 L · 6 cyl · Automatic 4-spd · Rear-Wheel Drive · about $4,450/year to fuel
Savana 1500/2500 2WD (cargo)
15mpg combined
City / highway
13 / 17 mpg
Fuel
Regular Gasoline
5.3 L · 8 cyl · Automatic 4-spd · Rear-Wheel Drive · about $4,450/year to fuel
Savana 1500/2500 2WD (Passenger)
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
Savana 1500/2500 2WD (Passenger)
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
Savana 15/25 AWD Conversion (cargo)
14mpg combined
City / highway
13 / 17 mpg
Fuel
Regular Gasoline
5.3 L · 8 cyl · Automatic 4-spd · 4-Wheel or All-Wheel Drive · about $4,800/year to fuel
Savana 1500/2500 AWD (cargo)
14mpg combined
City / highway
13 / 17 mpg
Fuel
Regular Gasoline
5.3 L · 8 cyl · Automatic 4-spd · 4-Wheel or All-Wheel Drive · about $4,800/year to fuel
Savana (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
Savana 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
Savana 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
Savana 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*
Steering Gear box › Shaft pitman; Linkages › Arm › Idler and attachment
2
0
0
0
—
Power train Automatic transmission
2
0
1
0
—
Fuel system, gasoline Delivery
2
0
0
0
—
Service brakes, hydraulic
2
0
0
0
—
Engine and engine cooling
1
0
0
0
—
Suspension Rear
1
0
1
0
—
Exterior lighting Tail lights
1
0
1
0
—
Air bags Frontal
1
1
0
1
—
Seat belts Rear/other
1
0
0
0
—
Seats Front assembly › Recliner
1
0
0
0
—
Fuel/propulsion system
1
0
0
0
—
Unknown or other
1
1
0
1
—
*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.
Recent owner complaints
Oct 1, 2022 · 92,000 milesService brakes, hydraulic The contact owns a 2004 GMC Savana. The contact stated that while driving at an undisclosed speed, the brake pedal went to the floorboard while depressed. The dealer was made aware of the failure and scheduled an upcoming appointment; however, the vehicle was not diagnosed nor repaired. The manufacturer was made aware of the failure and informed the contact that there was no recall associated with the VIN. The contact related the failure to NHTSA Campaign Number: 04V045000 (Service Brakes, Hydraulic) however, the VIN was not included in the recall. The failure mileage was approximately 92,000.
Nov 16, 2019Wheels PROBLEM IS WITH A NEW TIRE PURCHASE BF GOODRICH LT245/75R16 BFG COMMERCIAL TA A/S2. I NOTICE FLAT SPOTTING EVERY MORNING AND IT COULD TAKE 1/2 HR OF DRIVING TO CLEAR UP BEEN DRIVING FOR OVER 60 YRS AND HAVE NEVER EXPERIENCED THIS BEFORE. I CONSIDER THIS TO BE A BAD TIRE. IF IT HAS FLAT SPOTS WITH 70PSI AND MIN. LOAD WHAT WILL HAPPEN WITH FULL LOAD. RETURNED TO DEALER BUT HE FAILS TO SEE A PROBLEM. I WAS PARKED 12HRS AND PROBLEM APPEARS EACH MORNING. I FEEL VERY UNCOMFORTABLE WITH THIS TIRE ON MY TRUCK.
Feb 23, 2012 · crash · 1 injuryUnknown or other SUBMISSION FROM EXPLORER VAN CO., RE RECEIPT OF YOUR CORRESPONDENCE DATED JULY 10, 2014 REGARDING THE EARLY WARNING REPORTING OF DEATHS AND INJURIES. *SMD THE DRIVER WAS INVOLVED IN AN ACCIDENT, WHILE DRIVING A 2004 GMC SAVANA, WHICH RESULTED IN SERIOUS AND PERMANENT INJURIES. *JB
Jun 3, 2013 · 63,000 milesPower train THE VEHICLE IS OUT OF WARRANTY. HOWEVER, IT ONLY HAS 63K PLUS MILES ON THE ODOMETER. THE TRANSMISSION SUDDENLY BECAME ERRATIC. IT WOULD NOT SHIFT TO "D", BUT THE SECOND AND THE FIRST GEAR WORKS FINE. WE WERE TOLD BY GMC CUSTOMER SERVICE TO HAVE IT INSPECTED AND HAVE IT DIAGNOSED BY A GMC DEALER TO FIND OUT THE EXACT CAUSE OF THE PROBLEM. THE RESULTS INDICATED NO PROBLEMS WERE DETECTED OR NO CODES WERE SHOWING UP ON THEIR COMPUTER, GMC THEN TOLD US THAT IT NEEDS A NEW TRANSMISSION. WE COULD NOT AFFORD A NEWLY REBUILT TRANSMISSION.
Dec 6, 2012 · 96,000 milesFuel system, gasoline NO INCIDENT ...YET. NOTICED THE SMELL OF GAS AFTER REFUELING JUST BEFORE CHRISTMAS 2012. IT HAS BEEN GETTING WORSE EVER SINCE. CHECKED OUT RECALLS AND SAW THIS ONE, BUT NEVER RECEIVED A RECALL NOTICE. CALLED LOCAL DEALER AND TOLD ME THAT IT WAS NOT COVERED. SOMETHING IS WRONG HERE. THIS RECALL (LISTED BELOW) IS EXACTLY WHAT IS THE ISSUE WITH MY GMC VAN. IT SHOULD BE INCLUDED IN THIS RECALL BUT FOR SOME REASON IS NOT. I AM GOING TO FIX IT MYSELF (AT MY OWN EXPENSE), BECAUSE IT IS A SAFETY ISSUE AND I AM NOT GOING TO RISK THE SAFETY OF MY FAMILY. FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP RECALL NUMBER: 12V388000 RECALL DATE: 08/08/2012 PROBLEM SUMMARY: GENERAL MOTORS…
Feb 10, 2009 · 87,927 milesService brakes, hydraulic TL*THE CONTACT OWNS A 2004 GMC SAVANA. WHILE DRIVING LESS THAN 20 MPH AND APPROACHING A STOP SIGN, THE BRAKE PEDAL EXTENDED TO THE FLOOR. THE CONTACT HAD TO USE MAXIMUM EFFORT IN ORDER FOR THE BRAKES TO CATCH. HIS VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER 05V043000. THE FAILURE AND CURRENT MILEAGES WERE LESS THAN 87,927.
Jul 9, 2007 · 28,850 milesFuel system, gasoline › Delivery FUEL LINE FROM GAS TANK TO "QUICK CONNECT" SPLIT NEAR THE MUFFLER. WITH THE PRESSURE OF THE FUEL PUMP, GASOLINE WAS SPEWING OUT OF THE LINE UNDER THE TRUCK NEAR THE MUFFLER. IT HAD HAPPENED TWO WEEKS OR SO EARLIER BUT I DIDN'T NOTICE IT BECAUSE I'D HAD A GAS SPILL FROM A LEAF BLOWER IN THE BACK OF THE VAN AND THOUGHT THAT WAS THE SMELL (EVEN THOUGH I'D WIPED IT UP). I WENT TO MY MECHANIC TO SEE IF HE COULD CLEAN THE SPILL. HE FOUND THE SPLIT THAT WAS CAUSING THE ODOR. IT WOULD SEEM TO BE A REAL FIRE HAZARD. THE FUEL LINE IS PLASTIC, MY MECHANIC SAYS, AND THERE ARE VERY FEW AVAILABLE (NONE AT FACTORY WAREHOUSES). *TR
Aug 22, 2005 · 17,000 milesSeat belts › Rear/other DT: THE CONTACT COMPLAINED ABOUT A SEAT BELT FAILURE. THE SECOND ROW RIGHT SIDE PASSENGER'S SEAT BELT WAS INSERTED BACKWARDS INTO THE BUCKLE. THE SEAT BELT LOCKED IN THE BUCKLE AND WOULD NOT RELEASE. THE SEAT BELT WAS CUT TO RELEASE THE PASSENGER. THE VEHICLE WAS SEEN BY THE DEALER, WHO ORDERED THE APPROPRIATE PARTS FOR THE REPAIR. THE PARTS HAVE NOT ARRIVED, THEREFORE, NO REPAIRS HAVE BEEN MADE . *AK THE DRIVER SEAT RECLINER WAS NOT WORKING. UPDATED 03/17/06. *JB
Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.