Most common 2004 Chevrolet Express 1500 problems
Share of the 12 complaints; one complaint can involve more than one system. "~" is the median mileage when the problem started.
Chevrolet Express 1500 complaints by model year
Best Express 1500 years: 2011, 2000, 2001. Years to avoid: 2003. Compare all years →
What 2004 Chevrolet Express 1500 owners say
Brakes
2004 Chevrolet Express g-van engine overheated causing smoke to come from driver cabinet and engine shut off. The consumer experienced the problem on 4 separate occasions. The brake master cylinder was replaced.
ABS engages at slow speed, at tail end of braking, even on dry surfaces. This has been going on for at least eight months. Started sometime in early summer/late spring 2008.
Fuel & propulsion system
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.
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. …
2004 Chevrolet Express 1500 engines & fuel economy
| Engine | Transmission | Drive | MPG city / hwy / combined |
|---|---|---|---|
| 5.3L 8-cyl | 4-speed automatic | 4WD/AWD | 13 / 17 / 14 |
EPA ratings. Class: Van.
Frequently asked questions
Is the 2004 Chevrolet Express 1500 a good car?
Based on 12 owner complaints filed with NHTSA, the 2004 Express 1500 rates average: 1.6× as many complaints as a typical year of the Express 1500 at the same age. Complaint counts don't account for sales volume or individual maintenance, so have any used car inspected before buying.
What is the most common problem with the 2004 Chevrolet Express 1500?
The brakes — 3 complaints, 25% of all complaints for this model year, most often about foundation components › master cylinder. Next are the fuel & propulsion system (3) and windows, wipers & sunroof (2).
How many recalls does the 2004 Chevrolet Express 1500 have?
NHTSA lists no recalls for the 2004 Chevrolet Express 1500. You can still confirm with your VIN using our VIN recall check.
What are the best and worst years of the Chevrolet Express 1500?
The best years by complaints, compared at the same age, are 2011, 2000 and 2001. Years to avoid or approach with caution: 2003. See the full Chevrolet Express 1500 years comparison.
At what mileage do 2004 Chevrolet Express 1500 problems happen?
The median mileage reported in complaints is about 114,000 miles; 40% of problems with a recorded mileage started before 50,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.