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2004 Chevrolet Express 2500 problems

The most common problem on the 2004 Chevrolet Express 2500 is brakes. Its complaint count is close to a typical Express 2500 model year.

Typical yearClose to a typical year
Owner complaints
8
Recalls
1
Service bulletins
94
Worst area
Brakes

The worst 2004 Chevrolet Express 2500 problems

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

  • Brakes
    3
  • Transmission
    3
  • Engine
    2
  • Electrical
    1

Problems by type

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

  • Brakes
    3
  • Transmission
    3
  • Engine
    2
  • Electrical
    1

Recalls 1

Exterior lightingReported December 13, 2005 · 2 vehicles affected
What is wrong
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.
Risk
Following vehicles may not be fully informed of vehicle braking. Rear-end crashes and injury to occupants may occur.
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.

Recall number 05V559000 · Recall details

See all 1 recalls for the 2004 Chevrolet Express 2500

Technical service bulletins for the 2004 Chevrolet Express 2500 94

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

See all 94 bulletins for the 2004 Chevrolet Express 2500

What 2004 Chevrolet Express 2500 owners say

Most recent owner complaints, unedited.

Filed Oct 5, 2016 · Brakes · 115,000 miles · VA

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 the federal safety agency 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.

Filed Aug 2, 2013 · Transmission · 119,000 miles · NY

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.

Filed Feb 6, 2012 · Engine · 15,500 miles · FL

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

Filed Jun 14, 2010 · Engine, Transmission · 103,000 miles · NY

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.

Filed Apr 15, 2010 · Transmission · NY

Repeated cracked flywheel. Original cracked just over 100k miles. Replacement now cracked 40k miles later.

Filed Jan 15, 2010 · Brakes, Electrical · 26,500 miles · IA

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.

Filed Jun 7, 2006 · 21,000 miles · IL

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.

Filed Dec 30, 2005 · Brakes · FL · crash

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.

Compare the 2004 Chevrolet Express 2500

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Questions about the 2004 Chevrolet Express 2500

Is the 2004 Chevrolet Express 2500 reliable?

Owners have filed 8 complaints about the 2004 Chevrolet Express 2500, close to a typical Express 2500 model year.

What is the most common problem with the 2004 Chevrolet Express 2500?

Brakes, with 3 complaints. Next is transmission (3).

How many recalls does the 2004 Chevrolet Express 2500 have?

1 recall, covering exterior lighting.

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