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2004 Chevrolet Express 1500 problems

The most common problem on the 2004 Chevrolet Express 1500 is brakes. It has 2.4 times the complaints of a typical Express 1500 model year.

Typical year2.4x the typical complaints
Owner complaints
12
Recalls
0
Service bulletins
90
Worst area
Brakes
Fuel economy
12-15mpg

The worst 2004 Chevrolet Express 1500 problems

Ranked by number of owner complaints. Mileage and cost come from what owners wrote.

  • Brakes
    3
  • Fuel system
    3
  • Airbags
    2
  • Engine
    2
  • Visibility
    2

Problems by type

Tap a problem to see which part fails, at what mileage and in which other years.

  • Brakes
    3
  • Fuel system
    3
  • Airbags
    2
  • Engine
    2
  • Visibility
    2
  • Body
    1
  • Electrical
    1
  • Tires
    1

Recalls

No recalls on record for this model year.

Technical service bulletins for the 2004 Chevrolet Express 1500 90

Bulletins tell dealers how to fix known problems. A warranty extension means the manufacturer pays for that repair for longer.

See all 90 bulletins for the 2004 Chevrolet Express 1500

2004 Chevrolet Express 1500 fuel economy

Official EPA estimates in miles per gallon (MPGe for electric). Ranges cover trims that share the same engine.

EngineDriveCityHighwayCombined
4.3L 6‑cylRWD131815
5.3L 8‑cylRWD141815
5.3L 8‑cyl4WD131714
6.0L 8‑cylRWD111512

What 2004 Chevrolet Express 1500 owners say

Most recent owner complaints, unedited.

Filed Jan 20, 2019 · Fuel system · 33,000 miles · TN

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

Filed Jan 31, 2016 · Fuel system · 160,000 miles · RI

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.

Filed May 29, 2015 · Airbags, Body · 250,000 miles · VA · crash · 1 injury

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.

Filed Aug 22, 2012 · Fuel system · 114,000 miles · CT

Tl* the contact owns a 2004 chevrolet express. The contact stated that after refueling, fuel spew back out of the filler neck. The manufacturer was made aware of the failure who did not offer any assistance since the vehicle was not included in the federal safety agency campaign id number: 12v388000 (fuel system, gasoline: storage: tank assembly: filler pipe and cap). The failure and current mileage was 114,000. Updated 10/16/12*lj the consumer stated the fuel filler neck corroded updated 10/19/2012

Filed May 17, 2011 · Tires · NY

We purchased a complete set of general grabber hts 235/75r16 for our chevy express van at dunn tire on 11/15/08. They were supposed to have a 60k warranty. We went in for the required rotations and noted that the tread didn't seem to be wearing well. At the 20k mile rotation in january of 2011, dunn tire acknowledged that the tires were not performing as advertised and told us that they would likely need to adjust the tires on a pro-rata basis at the next rotation at 25k miles. It is our belief that the tires are defective in some way. The original tires on our van lived up to their 40k warranty and we replaced with these grabber hts tires at 39747 miles. Our driving habits are conservative and we have never had to replace tires ahead of the warranty period. The tread was so bad on these grabber hts tires that we were unable to drive our van on snowy roads during this past winter. We also were concerned about hydroplaning on the expressway when we drove the van through heavy rains this past weekend when we dropped off our daughter at college. We believe these tires are hazardous and that an investigation should be initiated. It's inconceivable that we would only get 25k miles out of a 60k tires. We feel cheated and really do not want another set of general tires on a pro-rata basis.

Filed Jan 30, 2010 · Brakes · 18,580 miles · OH

2004 chevy express 1500.

Filed Mar 30, 2009 · Brakes · 35,000 miles · MI

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.

Filed Mar 19, 2009 · Airbags · 91,048 miles · TX

The passenger side airbag employed when the vehicle was parked inside the shop. The vehicle is available for inspection at stanley chevrolet celina tx 972‑382‑3000 contact gary werner service manager. The vehicle owner is rick dietel of amersol inc. 214‑503‑9977.

Filed Sep 24, 2008 · Visibility · 120,000 miles · PA

The windshield wipers will not turn off.

Filed Dec 26, 2007 · Electrical · 166,000 miles · CA · fire

Tl*the contact owns a 2004 chevrolet express 1500. The vehicle caught fire inside the fuse box after being parked for four days. The fire caused damage to the fuse box. As of december 26, 2007, the dealer had not inspected the vehicle. The purchase date was unknown. The current and failure mileages were 166,000.

Compare the 2004 Chevrolet Express 1500

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Questions about the 2004 Chevrolet Express 1500

Is the 2004 Chevrolet Express 1500 reliable?

Owners have filed 12 complaints about the 2004 Chevrolet Express 1500, 2.4 times a typical Express 1500 model year.

What is the most common problem with the 2004 Chevrolet Express 1500?

Brakes, with 3 complaints. Next is fuel system (3).

How many recalls does the 2004 Chevrolet Express 1500 have?

No recalls on record.

What gas mileage does the 2004 Chevrolet Express 1500 get?

Official estimates for the 2004 Chevrolet Express 1500 range from 12 to 15 mpg combined. The most efficient version (4.3L 6-cyl, RWD) gets 13 city and 18 highway.

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