2004 Chevrolet Express
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Chevrolet › Express › 2004
These records cover every 2004 Chevrolet Express. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
7 recalls name the 2004 Chevrolet Express. Newest first.
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…
Risk and remedy
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.
Remedy
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.
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…
Risk and remedy
Risk
Decreased lighting visibility may result in a vehicle crash.
Remedy
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.
On certain full-size passenger, cargo, or cutaway vans, the front and rear seat belt buckles will not latch or will not unlatch.
Risk and remedy
Risk
In the event of a crash, a seat occupant may not be properly restrained increasing the risk of personal injury.
Remedy
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.
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 and remedy
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.
Remedy
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.
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 and remedy
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.
Remedy
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.
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 and remedy
Risk
The safety belt may not restrain the occupant as intended during a crash, which could result in injury to the occupant.
Remedy
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.
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 and remedy
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.
Remedy
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.
Owner complaints
21 complaints1 involved a crash2 involved a fire
What owners report most
Latest complaints
- Fuel/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.
- Service brakes · Suspension
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…
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.
- Fuel/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
- Visibility/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…
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
- Structure › 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.
- Seat belts
Two rear bucket seat belt cables have broken without impact.
- Engine
Engine exhaust manifold broken bolts,has 3 at this point and time. This causes the exhaust to leak into drivers compartment. *tr
- Service 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…
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.
- Power train › Automatic transmission › Lever and linkage › Column shift
TL* the contact owns a 2004 chevrolet express. The contact stated that while attempting to shift into park, the linkage popped off preventing the vehicle from being shifted into park. The emergency brake was engaged in order to prevent the vehicle from moving. The vehicle was diagnosed with a…
TL* the contact owns a 2004 chevrolet express. The contact stated that while attempting to shift into park, the linkage popped off preventing the vehicle from being shifted into park. The emergency brake was engaged in order to prevent the vehicle from moving. The vehicle was diagnosed with a failed cable assembly that needed to be replaced. The vehicle was repaired. The manufacturer was notified of the failure. The failure mileage was 120,000 and the current mileage was 136,000.
- Structure › Body
TL* the contact owns a 2004 chevrolet express g1500. The contact stated that the driver and passenger side double door hinges failed and the doors could not be opened. The dealer advised that the door hinges needed to be replaced. The vehicle was not repaired. the manufacturer was not made aware of the failure. The approximate failure mileage was 109,000 and the approximate failure mileage was 110,00.
- Service brakes · Steering
Vehicle has continued to evidence problems similar to what's described by nhtsa campaign ID no. 04V452000. Power steering pump and belts have been replaced and gm dealer performed hydro boost inspection test and it passed; said no further action required. Bus has again lost power steering and brakes to cause a dangerous condition. Dealer says it IS not a vehicle that recall applies to. *js
- Service brakes, hydraulic
While traveling down a steep grade while applying the brakes, a severe shaking of the steering wheel and wheels occurred. it was so severe the steering wheel shook out of my hands. once back on level grade for a mile or so, applying the brakes didn't result in the severe shaking. from that point…
While traveling down a steep grade while applying the brakes, a severe shaking of the steering wheel and wheels occurred. it was so severe the steering wheel shook out of my hands. once back on level grade for a mile or so, applying the brakes didn't result in the severe shaking. from that point on while driving on any steep hill or mountain, the same thing occurs. the brake pads and rotors were replaced last year, but that has not fixed the issue.
- Parking brake · Service brakes, hydraulic
On june 20TH, 2008 we brought our van in for a routine brake inspection and wheel alignment at 36,117 miles. we also noticed a noise in the rear when making a turn. the mechanic indicated that the brake backing plates on both sides were rusted, and the left rear backing plate was rotted to the…
On june 20TH, 2008 we brought our van in for a routine brake inspection and wheel alignment at 36,117 miles. we also noticed a noise in the rear when making a turn. the mechanic indicated that the brake backing plates on both sides were rusted, and the left rear backing plate was rotted to the point that it had holes in it. the mechanic indicated that the replacement parts were inexpensive, but the labor was intensive and would probably cost in the neighborhood of $600. we have not repaired the backing plates yet because this vehicle has other quality issues and we are considering a replacement vehicle. *Tr
- Service brakes, hydraulic
My anti-lock brakes activate at low speeds. we first noticed it around 37,000 miles, but now it occurs almost every time we apply the brakes at low speed at 39,000 miles. we discussed the problem with two chevy garages - both admitted that it was a common, known corrosion problem that requires…
My anti-lock brakes activate at low speeds. we first noticed it around 37,000 miles, but now it occurs almost every time we apply the brakes at low speed at 39,000 miles. we discussed the problem with two chevy garages - both admitted that it was a common, known corrosion problem that requires either cleaning the brake sensors for approximately $200 or replacing them at a cost of approximately $460. this IS a huge safety issue for us. the van drifts forward too far when we stop and we are concerned that we will either hit another car or possibly a pedestrian. we are concerned that this will be an ongoing problem with the vehicle as we are located in new york state and salt IS a common winter corrosive. *Tr
- Seat belts
Dt*: the contact stated the seat belt buckle did not release the seat belt properly. intermittently, the seat belt became stuck in the buckle. the notice for nhtsa recall #05v558000, pertaining to the seat belts, was received. the vehicle was taken to a service dealer, where the dealer denied a…
Dt*: the contact stated the seat belt buckle did not release the seat belt properly. intermittently, the seat belt became stuck in the buckle. the notice for nhtsa recall #05v558000, pertaining to the seat belts, was received. the vehicle was taken to a service dealer, where the dealer denied a free remedy due to the problem only being intermittent. the manufacturer was notified, who stated the buckle assembly would only be replaced if the problem could be replicated at the dealership.
- Seat belts › Front › Buckle assembly
Consumer complaint concerning the poor quality of gm and gmac products. *ts the consumer received a recall notice regarding the front buckle assembly on his seat belt. the consumer had already been experiencing problems prior to the recall. *jb
- Air bags
Air bags failed on crash. *nm
- Fuel system, gasoline › Delivery › Fuel pump
Our 2004 chevy express van stalled serveral(12) times within a 14 mile distance on the interstate in denver, co. the wife was able to get it home, and we contacted the local chevy dealer (stevenson chevy, golden co.) the service advisor advised us that chevy IS having a problem with fuel pumps…
Our 2004 chevy express van stalled serveral(12) times within a 14 mile distance on the interstate in denver, co. the wife was able to get it home, and we contacted the local chevy dealer (stevenson chevy, golden co.) the service advisor advised us that chevy IS having a problem with fuel pumps overheating and IS working the problem. no recall has been issued for the fuel pump problem from chevy. yes, the fuel pump was replace at sevenson chevy in golden, co on 21 july. this IS our second occurance of a fuel pump failure in a new chevy vehicle. our first occurance was in our new 2001 tahoe, where it stranded us in the middle of kansas, when the fuel pump failed.
- Electrical system › 12v/24v/48v battery · Electrical system › Alternator/generator/regulator · Engine and engine cooling › Engine
Dt: the vehicle IS a 2004 chevrolet express 2500 van. On 7-11-05 the vehicle was making intermittent knocking noises. The vehicle was still able to go at this point. this had been going on for a couple of days. The problem had became worse, so the consumer took the vehicle to midas. the mechanic…
Dt: the vehicle IS a 2004 chevrolet express 2500 van. On 7-11-05 the vehicle was making intermittent knocking noises. The vehicle was still able to go at this point. this had been going on for a couple of days. The problem had became worse, so the consumer took the vehicle to midas. the mechanic told the consumer that the fly wheel had failed. The consumer had to replace the water pump, battery and the alternator . *jb
- Fuel system, gasoline › Delivery › Fuel pump
Three times our vehicle engine has abruptly stopped running in crowded interstate traffic, endangering the lives of us and occupants of adjacent vehicles. the first was august 7, 2004 on interstate 40 near kingman az. our first thought was that we ran out of gas, but the gauge registered !/4…
Three times our vehicle engine has abruptly stopped running in crowded interstate traffic, endangering the lives of us and occupants of adjacent vehicles. the first was august 7, 2004 on interstate 40 near kingman az. our first thought was that we ran out of gas, but the gauge registered !/4 full and when we added gas it took only 22.8 gallons (31 gallon tank). the second was may 23, 2005 on interstate 25 passing through colorado springs co. the gas tank was 3/4 full. fortunately, we were able to coast into the right lane and off to the right shoulder without causing an accident. we were towed to team chevrolet service department (719-380-6020) in colorado springs who found "lean code", suspected fuel pump problem, but vehicle seemed ok in 2 road test drives. On return home to albuquerque, galles chevrolet service department (505-766-6800) found codes p0174, p0171 and p0300. they replaced fuel pump module (part number 89060662, *module 3.107) at mileage 8,826 (june 9-16, 2005). the third time was on july 1, 2005 on interstate 40 approaching williams az in the middle of heavy truck traffic traveling at interstate speed limit (75 mph). we were in the left lane adjacent to guardrail with no left highway shoulder and we narrowly escaped causing a multi-vehicle crash. this time we were towed to tyrrell-marxen chevrolet service department (928-774-5268) in flagstaff az. they found "codes p0171 and p0174 traced to faulty fuel module". they replaced fuel module (part number 88965421 module ki 3.107) at mileage 10875 (july 2, 2005). we like our roadtrek 170 popular (class b conversion van), but after these three (3) serious automotive system failures (plus wiper motor failure) we have serious concerns about safety of us & others when these things occur unexpectedly in heavy, high-speed interstate traffic.
- Steering › Linkages › Knuckle › Spindle › Arm
Left front wheel disengaged from van at 55 miles per hour on the interstate due to a nut falling off of the spindle. This was a very dangerous and costly situation.
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Hydraulic 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…
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.
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 11010544This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.
- 11009156This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester and Vehicle Data Recorder tools, giving website address and step by step instructions to complete the update.
- 11007744This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature.
- 11007743This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature.
- 11007208This 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 should not use the information that is provided by the antilock braking system tire size selection.
- 11006621Vehicle 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 completed in parallel instead of the technician needing to update one module at a time. This allows a more streamlined approach for dealers and customers.
- 11006421GM 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 during removal and to package the core properly for return.
- 11004761This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up.
- 11004557This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim.
- 11002312This service bulletin provides information for dealers/technicians on Service Programming System (SPS) Error Codes E4398, E4399, E4401, E4403, M4404, M4413, M6954, M6955, E4414, E4423, E4491, E4492, or E6961 and resolution information.
- 11000576This Warranty Administration bulletin provides retail and wholesale service personnel with the policies/procedures and the warranty transaction submission procedures that support the Personal Property Damage process.
- 10252735This bulletin provides information for electrical ground repairs using new General Motors replacement fasteners with conductive finish.
- 10252163XM Audio Traffic And Travel Link Availability And Operation.
- 10251890This technical bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up.
- 10250775This service bulletin provides service information to technicians on guidelines to replace Oil Cooler, Oil Cooler Lines and Oil Tank if the engine was replaced where large amounts of debris has flowed throughout the oiling system.
- 10249980This Preliminary Information communication provides information to the technician about vibration complaints that are one of the most challenging complaints to accurately diagnose and repair. Technician will need to use Pico Oscilloscope Diagnostic Kit to effectively diagnosis vehicles. Technician should drive the vehicle will using the Pico Oscilloscope to record data. After the data is recorded it should be reviewed to determine the root cause of the concern. If a repair attempt made the concern better but not eliminated or had no affect at all, and are requesting assistance from General Motors Technical Assistance Center record another Pico file and save it to the computer. After the new Pico Oscilloscope data has been saved email the data to General Motors Technical Assistance Center in the subject line include ?Vibration? ?Business Associate Code? and the last 8 of the Vehicle Identification Number.
- 10249590This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim.
- 10249579This PI bulletin advises the technician on the proper way to install the pistons in an engine.
- 10249011This informational bulletin provides information for dealers/technicians on Headlamp, Tail Lamp, License Lamp or Fog/Driving Lamp Damage.
- 10248444Vehicle Recalls
- 10247780This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature.
- 10247681Information On Requests To Add OnStar Bluetooth Option.
- 10247552This service bulletin provides information on Concerns or Questions Regarding Installation of Dealer Installed Accessories.
- 10246952Programming And Activation Of Replacement OnStar Modules.
- 10246951Programming And Activation Of Replacement OnStar Modules.
- 10246631Expanded Availability for Remanufacture and Return (R&R) Electronic Control Modules
- 10246499Duramax Diesel Glow Plugs Difficult to Install Due to Carbon Buildup - New Glow Plug Bore Reamer Available
- 10245951Canadian Customers Unable To Place Calls And Turn By Turn Inoperative In The United States.
- 10245950Canadian Customers Unable To Place Calls In The United States
- 10245833Special Coverage Adjustment - Fuel Filler Pipe Corrosion
- 10245395This service bulletin provides a vibration analysis worksheet the technician can use in conjunction with the appropriate Vibration Analysis-Road testing procedure when diagnosing vibration concerns.
- 10244274This service bulletin provides information about the Hunter wheel Road Force balancers that should be utilized for all repairs requiring balance and Road Force measurement.
- 10244214This informational bulletin provides information for the IPC odometer programming method quick reference guide.
- 10244201This service bulletin provides information for dealers on how to submit a product information report (PIR) (Canada Only).
- 10242843The service bulletin advises the tech of a normal transmission shift condition and the delay in throttle response when the throttle plate is opened rapidly and advises the customer that it is normal for the delay.
- 10242298This Preliminary information communicates information that will need to be provided to TAC to aid in diagnosing if a vehicle comes in with misfire and DTC Codes P0300 - P0308 and/or P050D
- 10242262This service bulletin provides graphics, information and guidelines for engine component wear to assist service personnel as a guideline to perform necessary engine repairs and prevent unnecessary engine replacement.
- 10242252This technical bulletin provides information and a solution to a condition of Brake Pedal Moves or Self Applies at Full Turns.
- 10240793This Preliminary Information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get record a sound clip or take a video of the noise for assessment by engineering. Technician will need to call General Motors Technical Assistance Center for further assistance.
- 10240344This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.
Every Chevrolet Express model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.