NHTSA vehicle safety data

2004 Chevrolet Express 2500 Recalls & Complaints

The 2004 Chevrolet Express 2500 has 2 NHTSA recall campaigns and 8 owner complaints on file as of November 3, 2026. Recall repairs are usually free at an authorized Chevrolet dealer.

NHTSA recall and complaint data for the 2004 Chevrolet Express 2500. Recall data is refreshed daily from NHTSA.

2004 Chevrolet Express 2500 owner complaints

Owners have filed 8 complaints with NHTSA about the 2004 Chevrolet Express 2500, describing incidents dated June 7, 2006 to April 7, 2014.

Most-cited components

Power Train 3 complaints
Service Brakes 3 complaints
Engine 2 complaints
Electrical System 1 complaint
Equipment 1 complaint

Of the 8 complaints on file, 1 reports a crash (owner-reported, not verified by NHTSA).

Newest complaints

ODI #10913946 · Filed October 5, 2016
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…
ODI #10533187 · Filed August 2, 2013
TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 2500. THE CONTACT STATED WHENEVER AT AN IDLE A LOUD METAL TO METAL NOISE WOULD EMIT CONTINUOUSLY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC ON TWO SEPARATE OCCASIONS WHERE THE CRACKED FLYWHEEL WAS REPLACED EACH TIME. THE MANUFACTURER WAS NOT…
ODI #10447592 · Filed February 6, 2012
AS I ATTEMPTED TO SPEED UP IN TRAFFIC, I HEARD A NOISE AND THE VEHICLE SUDDENLY SLOWED DOWN. I WAS ABLE TO GET IT OFF THE HIGHWAY ON TO A SIDE ROAD. ONCE THERE, IT WOULD NOT START. ON CLOSER INSPECTION, I SAW THAT THE BELT HAD COME APART AND OFF THE PULLEY'S. I HAD THE VAN TOWED TO MY HOME AND…

Read all 8 complaints

AFTERMARKET FUEL FILTERS/FUEL LEAK

NHTSA #06E043000 · Fuel System, Gasoline · NHTSA notice

Reported May 19, 2006 · HONEYWELL INTERNATIONAL, INC.

Potentially affected: 88,303 vehicles

Owners notified October 18, 2006

Defect description

CERTAIN REPLACEMENT FUEL FILTERS, FRAM BRAND NAME P/N G3727, WITH DATE CODES X52911 THROUGH X60801 SEQUENTIALLY OR X600141 AND A MEXICO COUNTRY OR ORIGIN MARKING ON THE FUEL FILTER HOUSING MANUFACTURED FROM OCTOBER 18, 2005, THROUGH MARCH 21, 2006, SOLD FOR USE ON THE VEHICLES LISTED ABOVE AND ON CERTAIN SCHOOL BUSES. (TO SEE THE SCHOOL BUS ENGINE SIZES, CLICK ON "DOCUMENT SEARCH" AND THEN "BUS APPLICATIONS"). THE CONNECTOR ON THE FUEL FILTER WAS NOT MANUFACTURED TO HONEYWELL'S SPECIFICATION. AS A RESULT, THE O-RING MAY NOT SEAT CORRECTLY ON THE FUEL LINE.

Safety consequence

THIS CONDITION MAY CAUSE AN INADEQUATE SEAL AT THE CONNECTION, POTENTIALLY LEADING TO A FUEL LEAK. IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.

Manufacturer remedy

HONEYWELL WILL NOTIFY OWNERS AND REPLACE THE FUEL FILTERS FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 18, 2006. OWNERS MAY CONTACT FRAM CUSTOMER SERVICE AT 1-800-890-2075 (OPTION 1).

Notes

THIS RECALL ONLY PERTAINS TO AFTERMARKET FRAM FUEL FILTERS AND HAS NO RELATION TO ANY ORIGINAL EQUIPMENT INSTALLED ON THE VEHICLES LISTED.CUSTOMERS MAY CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.

CENTER HIGH MOUNTED STOP LAMP/FMVSS 108

NHTSA #05V559000 · Exterior Lighting · NHTSA notice

Reported December 13, 2005 · QUALITY COACHES INC.

Potentially affected: 2 vehicles

Manufacturer campaign VCCBLCHV · Owners notified November 23, 2005 · Vehicles built May 1, 2005 – August 31, 2005 (per NHTSA)

Defect description

CERTAIN CONVERSION VANS BUILT ON GMC/CHEVROLET CHASSIS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES AND ASSOCIATED EQUIPMENT." THE HOUSING LENS OF THE CENTER HIGH MOUNTED STOP LAMP DOES NOT ALLOW ENOUGH LIGHT TO EMIT FROM THE LAMP.

Safety consequence

FOLLOWING VEHICLES MAY NOT BE FULLY INFORMED OF VEHICLE BRAKING. REAR-END CRASHES AND INJURY TO OCCUPANTS MAY OCCUR.

Manufacturer remedy

QUALITY COACHES IS WORKING WITH AUDIOVOX TO REPLACE THE CENTER HIGH-MOUNTED BRAKE LAMP ASSEMBLY. OWNERS MAY CONTACT QUALITY COACHES AT 1-800-373-6357 OR ASA AT 1-800-274-1886.

Notes

QUALITY/ASA RECALL NO. VCCBLCHV.CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

try.vin has no NCAP crash-test rating on file for the 2004 Chevrolet Express 2500. NHTSA rates some vehicles by body style — pickups by cab, vans by roof height — so check nhtsa.gov/ratings.

8 owner complaints have been filed with NHTSA for the 2004 Chevrolet Express 2500.

Service Brakes

ODI #10913946

Incident: April 7, 2014 · Filed: October 5, 2016

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.

Power Train

ODI #10533187

Incident: August 8, 2012 · Filed: August 2, 2013

TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 2500. THE CONTACT STATED WHENEVER AT AN IDLE A LOUD METAL TO METAL NOISE WOULD EMIT CONTINUOUSLY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC ON TWO SEPARATE OCCASIONS WHERE THE CRACKED FLYWHEEL WAS REPLACED EACH TIME. THE MANUFACTURER WAS NOT NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 119,000.

Engine and Engine Cooling

ODI #10447592

Incident: May 26, 2010 · Filed: February 6, 2012

AS I ATTEMPTED TO SPEED UP IN TRAFFIC, I HEARD A NOISE AND THE VEHICLE SUDDENLY SLOWED DOWN. I WAS ABLE TO GET IT OFF THE HIGHWAY ON TO A SIDE ROAD. ONCE THERE, IT WOULD NOT START. ON CLOSER INSPECTION, I SAW THAT THE BELT HAD COME APART AND OFF THE PULLEY'S. I HAD THE VAN TOWED TO MY HOME AND SUBSEQUENTLY, FIXED/REPLACED THE BELT. SINCE THAT TIME, I BEGAN TO HEAR A LOW KNOCKING, MORE SO WHEN I TURNED ON THE AIR CONDITIONING. WHEN IT BECAME LOUDER ON ALL GEARS AND WHILE PARKED, I TOOK IT TO HOLLER DRIVERS MART, IN WINTER PARK, FL. ON 01/19/2012, I WAS TOLD THAT THE FLYWHEEL HAD SHEARED AROUND THE AREA WHERE IT WAS BOLTED ONTO THE TRANSMISSION AND CONNECTED TO THE ENGINE. IT ALSO HAD FRACTURES IN AND AROUND THE SAME AREA OF THE SHEARING. TECH INFORMED ME THAT I HAD CAUGHT THE PROBLEM BEFORE A SERIOUS INCIDENT MAY HAVE OCCURRED. I HAVE THE FLY WHEEL AND WILL SEND PHOTOS. CONSUMER SENT IN PHOTOS. 02/07/12 UPDATED 02/07/12 *BF STATUS UPDATE 02/23/12

Engine and Engine Cooling; Power Train

ODI #10336168

Incident: May 20, 2010 · Filed: June 14, 2010

MYSTERIOUS COOLANT LEAK. RESERVOIR IS LOW AND NEEDS REFILLING OFTEN. MECHANIC HAS PERFORMED PRESSURE TEST TO NO AVAIL. NO COOLANT ON GROUND AT ANY POINT. NO VISIBLE SIGNS OF LEAK. THIS BEGAN RIGHT AFTER 2ND CRACKED FLYWHEEL WAS REPLACED. AT THE SAME TIME A LIFTER KNOCK BEGAN AS WELL. 1ST FLYWHEEL WAS REPLACED AT 103K (3K OUTSIDE OF EXTENDED WARRANTY). 2ND FLYWHEEL REPLACED AT 143K. VAN IS KEPT IN MINT CONDITION, OIL CHANGED EVERY 3K W/O FAIL. VEHICLE SEEMS TO BE IN OTHERWISE TERRIFIC CONDITION. 1ST AND ONLY OWNER. DATE REFERRED TO IS DATE OF 2ND FLYWHEEL CRACK. *TR

Power Train

ODI #10325828

Incident: April 15, 2010 · Filed: April 15, 2010

REPEATED CRACKED FLYWHEEL. ORIGINAL CRACKED JUST OVER 100K MILES. REPLACEMENT NOW CRACKED 40K MILES LATER. *TR

Service Brakes, Hydraulic; Electrical System

ODI #10299911

Incident: January 9, 2010 · Filed: January 15, 2010

I OWN A 2004 SILVERADO 2500 HD WITH 26,500 MILES ON IT. I HAD MY TRUCK SERVICED FOR SPEEDOMETER THAT WAS NOT WORKING AND WAS TOLD BY KARL CHEVY HERE IN ANKENY, IA THAT ALL OF MY ROTORS AND BRAKE PADS NEEDED TO BE REPLACED BECAUSE OF RUST. GM OUGHT TO FIX MY BRAKES FOR FREE, THEY NEED TO RECALL. I AM 61 AND HAVE OWNED A FEW AUTOMOBILES AND HAVE NEVER HAD TO REPLACE ROTORS WITH SUCH LOW MILEAGE. THE MAJORITY OF MILES ARE HIGHWAY. I HAVE BEEN IN A RIDESHARE POOL USING A METRO VAN PROVIDED TO OUR POOL FOR THE LAST FOUR YEARS AS THE MAIN DRIVER. *TR

Equipment

ODI #10159219

Incident: June 7, 2006 · Filed: June 7, 2006

DT*: THE CONTACT STATED THE ELECTRICAL MODULE THAT CONTROLS THE AUDIO WARNING SYSTEM IS LOCATED IN THE ORIGINAL RADIO. THE CONTACT SWITCHED THE RADIO AND LOST ALL OF THE AUDIO WARNING SYSTEMS. THE DEALER AND MANUFACTURER WAS ALERTED AND DETERMINED THE MODULE WAS IN THE ORIGINAL RADIO AND IT SHOULD BE PUT BACK IN THE VEHICLE.

Service Brakes, Hydraulic

ODI #10147553

Crash

Filed: December 30, 2005

DURING A SUDDEN STOP CHEVY 2500 EXPRESS ABS BRAKES PULLED TO THE RIGHT OR LEFT. *TS THE CONSUMER STATED THE PROBLEM USUALLY OCCURRED DURING A PANIC STOP. THE CONSUMER STATED HE HAD THREE SEPARATE ACCIDENTS BECAUSE OF THE DEFECTIVE BRAKES. *JB

Other Chevrolet Express 2500 model years

Check your 2004 Chevrolet Express 2500 VIN

Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your Chevrolet Express 2500 at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.

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