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NHTSA recalls, safety ratings, and consumer complaints for the 2004 Chevrolet Express.
| Overall Rating | Not Rated |
| Frontal Crash | Not Rated |
| Side Crash | Not Rated |
| Rollover | Not Rated |
Component: FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP
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.
Consequence: 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.
Component: EXTERIOR LIGHTING
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.
Consequence: 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.
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.
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.
MY 2004 CUTAWAY CHEVY SOLD AS A 2005 FOUR WINDS HAS THE EXACT PROBLEM FOR THIS RECALL. RECALL NUMBER 12V388000 RECALL DATE 08/08/2012 COMPONENT FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP SUMMARY 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. CONSEQUENCE SIGNIFICANT CORROSION MAY ALLOW FUEL TO LEAK DURING REFUELING, AND IN THE PRESENCE OF AN IGNITION SOURCE; THERE IS AN INCREASED RISK OF FIRE. WHAT OWNERS SHOULD DO 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. THE EXPRESS 1500 I OWN IS CURRENTLY EXHIBITING THIS EXACT ISSUE, AND ALTHOUGH SOLD IN CA IN 2005, BASE VAN WAS MANUFACTURED IN INDIANA MODIFIED BY THOR MOTORHOMES. THIS STATE IS LISTED IN THE RECALL ABOVE. I'M AFRAID TO DRIVE IT, CAN'T AFFORD TO FIX THE ISSUE BEING DISABLED VET ON SMALL SSDI INCOME. IVE THE FEELING IT'S THE SAME MODEL RECALLED, BUT OF COURSE CHEVY WILL NOT REPAIR IT BECAUSE IT IS NOT SPECIFICALLY ON RECALL LIST LIKE THE LEFT SIDE CARGO DOOR MODELS THAT ARE BEING REPAIRED BY THE CHEVROLET GM DEALERS? PLEASE HELP
The 2004 Chevrolet Express has 7 NHTSA recalls and 57 consumer complaints on file. It received an overall safety rating of Not Rated out of 5 stars in NHTSA crash testing. The high number of complaints suggests potential reliability concerns — review the complaint details above before purchasing. For the most detailed information about a specific vehicle, decode its VIN using our free decoder above.
Enter a specific VIN to get the full report — specs, recalls, safety ratings, complaints, investigations, and technical service bulletins.
Component: SEAT BELTS
ON CERTAIN FULL-SIZE PASSENGER, CARGO, OR CUTAWAY VANS, THE FRONT AND REAR SEAT BELT BUCKLES WILL NOT LATCH OR WILL NOT UNLATCH.
Consequence: 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.
Component: SERVICE BRAKES, HYDRAULIC
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.
Consequence: 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.
Component: SERVICE BRAKES, HYDRAULIC
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.
Consequence: 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.
Component: SEAT BELTS:FRONT:BUCKLE ASSEMBLY
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.
Consequence: 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.
Component: POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:COLUMN SHIFT
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.
Consequence: 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.
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
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
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.
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.
TWO REAR BUCKET SEAT BELT CABLES HAVE BROKEN WITHOUT IMPACT.
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.
THE FUEL FILLER TUBE LEAKS FUEL, IS CORRODED. AND ALSO THE REAR FUEL TANK STRAP, AT THE TOP OF THE CHASSIS IS ALSO CORRODED, AND THE FUEL TANK IS HANGING DOWN, CAUSING A RISK AND FIRE HAZZARD AS IT IS VERY CLOSE TO THE DRIVESHAFT.
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.
I WAS TRAVELING EAST THRO AN INTERSECTION WHEN A TRUCK ON THE MY RIGHT RAMMED ME IN THE FRONT RIGHT SIDE OF MY CAR.I FELT THE CAR SPIN AND THE TRUCK ENDED UP IN MY RIGHT REAR BUMPER AND WHEN I CAME TO A STOP BOTH AIRBAGS DEPLOYED AND I WAS INJURED AND THE AIRBAGS EXPLODED AND I HAVE EYE DAMAGE TO MY RIGHT EYE AND NECK INJURY AND BACK INJURY. STILL SEEING SPINE DR. AND EYE DR EVERY 6 MONTHS. *TR
ENGINE EXHAUST MANIFOLD BROKEN BOLTS,HAS 3 AT THIS POINT AND TIME. THIS CAUSES THE EXHAUST TO LEAK INTO DRIVERS COMPARTMENT. *TR
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.
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.
Showing 15 of 57 complaints