Most common 2004 Chevrolet Express problems
Share of the 21 complaints; one complaint can involve more than one system. "~" is the median mileage when the problem started.
Chevrolet Express complaints by model year
Best Express years: 2025, 2012, 2015. Years to avoid: 2013, 2020, 2000, 1999, 2002. Compare all years →
2004 Chevrolet Express recalls (6)
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,…
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
NHTSA defect investigations
Federal safety investigators have looked into a possible defect involving the 2004 Chevrolet Express:
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 changes.
What 2004 Chevrolet Express owners say
Brakes
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 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.
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
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.
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 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.
Consumer complaint concerning the poor quality of GM and gmac products. 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.
2004 Chevrolet Express engines & fuel economy
| Engine | Transmission | Drive | MPG city / hwy / combined |
|---|---|---|---|
| 6.0L 8-cyl | 4-speed automatic | RWD | 11 / 15 / 12 |
EPA ratings. Class: Van.
Frequently asked questions
Is the 2004 Chevrolet Express a good car?
Based on 21 owner complaints filed with NHTSA, the 2004 Express rates average: 18% fewer complaints than a typical year of the Express 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?
The brakes — 6 complaints, 29% of all complaints for this model year. Next are the fuel & propulsion system (4) and seat belts (3).
How many recalls does the 2004 Chevrolet Express have?
There are 6 recalls for the 2004 Chevrolet Express, the most recent from August 8, 2012 (filler pipe and cap). Recall repairs are free at any authorized dealer — check whether yours has been done with the VIN recall check.
What are the best and worst years of the Chevrolet Express?
The best years by complaints, compared at the same age, are 2025, 2012 and 2015. Years to avoid or approach with caution: 2013, 2020, 2000, 1999 and 2002. See the full Chevrolet Express years comparison.
At what mileage do 2004 Chevrolet Express problems happen?
The median mileage reported in complaints is about 109,000 miles; 39% 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.