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NHTSA vehicle safety data

2004 Chevrolet Express Recalls & Complaints

The 2004 Chevrolet Express has 7 NHTSA recall campaigns and 21 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. Recall data is refreshed daily from NHTSA.

Pre-purchase inspection checklist → Reliability & 5-year cost forecast →

2004 Chevrolet Express owner complaints

Owners have filed 21 complaints with NHTSA about the 2004 Chevrolet Express, describing incidents dated June 17, 2005 to December 4, 2021.

Most-cited components

  • Service Brakes 6 complaints
  • Fuel/Propulsion System 4 complaints
  • Seat Belts 3 complaints
  • Engine 2 complaints
  • Steering 2 complaints
  • Structure 2 complaints

Of the 21 complaints on file, 1 reports a crash and 2 a fire (owner-reported, not verified by NHTSA).

Newest complaints

  • ODI #11454777 · Filed

    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.

  • ODI #11445566 · Filed

    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…

  • ODI #10925238 · Filed

    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

Read all 21 complaints

NHTSA defect investigations

NHTSA's investigations file lists the 2004 Chevrolet Express in 1 investigation. A listed model year means only that an investigation names it; it says nothing about any particular vehicle. An open investigation is not a finding that a safety defect exists, and NHTSA can close one without a recall.

Open and recently closed NHTSA defect investigations

Fuel Filler Pipe Corrosion

NHTSA #12V388000 · Fuel System, Gasoline — Storage — Tank Assembly — Filler Pipe and Cap · NHTSA notice

Reported August 8, 2012 · GENERAL MOTORS LLC

Potentially affected: 9,389 vehicles

Manufacturer campaign 12166 · Owners notified October 1, 2012 · Vehicles built May 20, 2003 – June 21, 2004 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

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.

Safety 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.

Manufacturer 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.

Notes

GM's campaign number is 12166.Owners 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 www.safercar.gov.

FMVSS 108/AFTERMARKET COMBINATION LAMPS

NHTSA #09E012000 · Exterior Lighting · NHTSA notice

Reported April 7, 2009 · SABERSPORT

Potentially affected: 16,270 vehicles

Owners notified May 11, 2009

Defect description

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.

Safety consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Manufacturer 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.

Notes

THIS RECALL ONLY PERTAINS TO AFTERMARKET REPLACEMENT EQUIPMENT AND HAS NO RELATION TO ANY ORIGINAL EQUIPMENT INSTALLED ON VEHICLES PRODUCED BY THE VEHICLE MANUFACTURER.IN ORDER TO DETERMINE IF YOUR AFTERMARKET LAMP ASSEMBLY IS AFFECTED BY THIS NONCOMPLIANCE, PLEASE REVIEW THE LIST OF MODEL NUMBERS PROVIDED TO US BY SABERSPORT.THE LIST CAN BE FOUND UNDER "DOCUMENT SEARCH" LOCATED AT THE BOTTOM OF YOUR SCREEN.OWNERS 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 <A HREF=HTTP://WWW.SAFERCAR.GOV>HTTP://WWW.SAFERCAR.GOV</A> .

SEAT BELT BUCKLES

NHTSA #05V558000 · Seat Belts · NHTSA notice

Reported December 19, 2005 · GENERAL MOTORS CORP.

Potentially affected: 425,593 vehicles

Manufacturer campaign 05113 · Owners notified March 15, 2006 · Vehicles built March 1, 2003 – July 31, 2004 (per NHTSA)

Defect description

ON CERTAIN FULL-SIZE PASSENGER, CARGO, OR CUTAWAY VANS, THE FRONT AND REAR SEAT BELT BUCKLES WILL NOT LATCH OR WILL NOT UNLATCH.

Safety consequence

IN THE EVENT OF A CRASH, A SEAT OCCUPANT MAY NOT BE PROPERLY RESTRAINED INCREASING THE RISK OF PERSONAL INJURY.

Manufacturer 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.

Notes

GM RECALL NO. 05113. 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.

HYDRO-BOOST/HYDRAULIC BRAKE/BOSCH

NHTSA #05V043000 · Service Brakes, Hydraulic · NHTSA notice

Reported February 8, 2005 · GENERAL MOTORS CORP.

Potentially affected: 77,411 vehicles

Manufacturer campaign 05006 · Owners notified March 23, 2005 · Vehicles built February 1, 2004 – July 31, 2004 (per NHTSA)

Defect description

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.

Safety 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.

Manufacturer 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.

Notes

GM RECALL NO. 05006.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.

GM/TRANSMISSION SHIFT CABLE SEPARATION

NHTSA #04V320000 · Power Train — Automatic Transmission — Lever and Linkage — Column Shift · NHTSA notice

Reported July 6, 2004 · GENERAL MOTORS CORP.

Potentially affected: 1,792 vehicles

Manufacturer campaign 04061 · Owners notified August 19, 2004 · Vehicles built May 18, 2004 – May 25, 2004 (per NHTSA)

Defect description

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.

Safety 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.

Manufacturer 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.

Notes

GM RECALL NO. 04061.CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

GM/FMVSS 209/SEAT BELT BUCKLE ASSEMBLY

NHTSA #04V189000 · Seat Belts — Front — Buckle Assembly · NHTSA notice

Reported April 19, 2004 · GENERAL MOTORS CORP.

Potentially affected: 331 vehicles

Manufacturer campaign 04025 · Owners notified May 7, 2004 · Vehicles built March 1, 2004 – April 30, 2004 (per NHTSA)

Defect description

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.

Safety consequence

THE SAFETY BELT MAY NOT RESTRAIN THE OCCUPANT AS INTENDED DURING A CRASH, WHICH COULD RESULT IN INJURY TO THE OCCUPANT.

Manufacturer 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.

Notes

GM RECALL NO. 04025.CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

GM/FMVSS 135/BRAKE VALVE

NHTSA #04V045000 · Service Brakes, Hydraulic · NHTSA notice

Reported February 4, 2004 · GENERAL MOTORS CORP.

Potentially affected: 68,875 vehicles

Manufacturer campaign 04004 · Owners notified June 18, 2004 · Vehicles built June 1, 2003 – June 30, 2003 (per NHTSA)

Defect description

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.

Safety 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.

Manufacturer 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.

Notes

GM RECALL NO. 04004.CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

Other Chevrolet Express model years

Check your 2004 Chevrolet Express VIN

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

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