the federal safety agency 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.
The worst 2004 Chevrolet Express problems
Ranked by number of owner complaints. Mileage and cost come from what owners wrote.
- Brakes6
- Fuel system4
- Seat belts3
- Body2
- Engine2
Problems by type
Tap a problem to see which part fails, at what mileage and in which other years.
- Brakes6
- Fuel system4
- Seat belts3
- Body2
- Engine2
- Steering2
- Airbags1
- Electrical1
- Suspension1
- Transmission1
- Visibility1
Recalls 6
Fuel system, gasoline: storage: tank assembly: filler pipe and cap
- What is wrong
- 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.
- Risk
- Significant corrosion may allow fuel to leak during refueling, and in the presence of an ignition source; there is an increased risk of fire.
- 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.
Recall number 12V388000 · Recall details
Seat belts
- What is wrong
- On certain full-size passenger, cargo, or cutaway vans, the front and rear seat belt buckles will not latch or will not unlatch.
- Risk
- In the event of a crash, a seat occupant may not be properly restrained increasing the risk of personal injury.
- 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.
Recall number 05V558000 · Recall details
Service brakes, hydraulic
- What is wrong
- 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.
- Risk
- 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.
- 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.
Recall number 05V043000 · Recall details
Power train: automatic transmission: lever and linkage: column shift
- What is wrong
- 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.
- Risk
- If this were to occur, the vehicle could move in a direction not anticipated by the driver, which could result in a vehicle crash.
- 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.
Recall number 04V320000 · Recall details
Seat belts: front: buckle assembly
- What is wrong
- 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.
- Risk
- The safety belt may not restrain the occupant as intended during a crash, which could result in injury to the occupant.
- 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.
Recall number 04V189000 · Recall details
Service brakes, hydraulic
- What is wrong
- 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.
- Risk
- 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.
- 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.
Recall number 04V045000 · Recall details
See all 6 recalls for the 2004 Chevrolet Express
Defect investigations
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. Gm made additional changes in november 1999, february 2000, may 2001, and february 2004.odi will continue to monitor this problem and will take further action, if warranted, in the future.for further technical details see the attached engineering analysis report.
EA04012
Technical service bulletins for the 2004 Chevrolet Express 591
Bulletins tell dealers how to fix known problems. A warranty extension means the manufacturer pays for that repair for longer.
- This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.
- This service bulletin provides information for dealers/technicians on OnStar Module 2G Sunset Information.
- This Preliminary Information communication provides information to the technician about vehicles that have...
- This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.
- This Preliminary Information communicates to the dealer the process for downloading or updating operating...
- This Preliminary Information communication provides information to the technician about vehicles that the...
- This Preliminary Information communication provides information to the technician about changing the tire...
- Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles
- GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities
- This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves...
2004 Chevrolet Express fuel economy
Official EPA estimates in miles per gallon (MPGe for electric). Ranges cover trims that share the same engine.
| Engine | Drive | City | Highway | Combined |
|---|---|---|---|---|
| 6.0L 8‑cyl | RWD | 11 | 15 | 12 |
What 2004 Chevrolet Express owners say
Most recent owner complaints, unedited.
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.
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
Tl* the contact owns a 2004 chevrolet express. While the vehicle was parked the rear driver's side window fell out of place. The contact stated that all the windows on the vehicle were loose. There no warning lights illuminated. The vehicle was not diagnosed or repaired. The manufacturer was notified of the issue. The failure mileage was 33,000. Updated 01/31/17*lj consumer stated drivers side rear seat lower window broke. Glue came off manufactured window made by c.r. Laurence co, inc. Window was replaced 11/08/16. Updated 6/22/18
The van was parked in my driveway stationary. It caught fire and proceeded to burn completely for unknown reasons. The website states this VIN number is not included in any recalls but the vehicle type has a recall listed that states it could be a fire hazard.
Two rear bucket seat belt cables have broken without impact.
Engine exhaust manifold broken bolts,has 3 at this point and time. This causes the exhaust to leak into drivers compartment.
Tl* the contact owns a 2004 chevrolet express. The contact stated that while driving 5 MPH and depressing the brake pedal, the ABS system prevented the vehicle from braking properly and the ABS warning light illuminated. In one occasion, the vehicle failed to stop and proceeded through the intersection during a red light. The vehicle was taken to a private mechanic where it was diagnosed that the brake sensors and the ABS main control system needed to be replaced. The manufacturer was notified of the failure. The vehicle was repaired but the failure recurred. The failure mileage was 110,000 and the current mileage was unknown.
Tl* the contact owns a 2004 chevrolet express. The contact stated that while attempting to shift into park, the linkage popped off preventing the vehicle from being shifted into park. The emergency brake was engaged in order to prevent the vehicle from moving. The vehicle was diagnosed with a failed cable assembly that needed to be replaced. The vehicle was repaired. The manufacturer was notified of the failure. The failure mileage was 120,000 and the current mileage was 136,000.
Tl* the contact owns a 2004 chevrolet express g1500. The contact stated that the driver and passenger side double door hinges failed and the doors could not be opened. The dealer advised that the door hinges needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The approximate failure mileage was 109,000 and the approximate failure mileage was 110,00.
Compare the 2004 Chevrolet Express
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Questions about the 2004 Chevrolet Express
Is the 2004 Chevrolet Express reliable?
Owners have filed 21 complaints about the 2004 Chevrolet Express, 1.4 times a typical Express model year.
What is the 2004 Chevrolet Express year score?
The 2004 Chevrolet Express scores 59 out of 100 (below average). The score compares it with the other model years of the Chevrolet Express: 75 is a typical year, 50 means twice the usual complaints, and serious complaints and recalls lower it.
What is the most common problem with the 2004 Chevrolet Express?
Brakes, with 6 complaints, typically around 65,000 miles. Next is fuel system (4).
How many recalls does the 2004 Chevrolet Express have?
6 recalls, covering fuel system, gasoline, seat belts and service brakes, hydraulic.
What gas mileage does the 2004 Chevrolet Express get?
Official estimates for the 2004 Chevrolet Express range from 12 mpg combined. The most efficient version (6.0L 8-cyl, RWD) gets 11 city and 15 highway.
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