RecallMyCar

2004 Chevrolet Express Recalls, Complaints & Specs

6 safety recalls list the 2004 Chevrolet Express, and owners have filed 21 complaints with NHTSA. Check your own VIN below.

6
safety recalls
21
owner complaints to NHTSA
1 / 2
complaints citing a crash / fire
12–15
MPG combined (EPA)

6 safety recalls for the 2004 Chevrolet Express

Most recent first. Recall repairs are free at any authorised dealer. Click a recall for the full defect, consequence and remedy text.

  1. Filler pipe and cap (fuel system)

    NHTSA 12V388000 Reported 9,389 vehicles potentially affected GENERAL MOTORS LLC

    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,…

    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…

  2. Seat belts

    NHTSA 05V558000 Reported 425,593 vehicles potentially affected GENERAL MOTORS CORP.

    On certain full-size passenger, cargo, or cutaway vans, the front and rear seat belt buckles will not latch or will not unlatch.

    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…

  3. Service brakes, hydraulic

    NHTSA 05V043000 Reported 77,411 vehicles potentially affected GENERAL MOTORS CORP.

    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.

    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,…

  4. Column shift (power train)

    NHTSA 04V320000 Reported 1,792 vehicles potentially affected GENERAL MOTORS CORP.

    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.

    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.

  5. Buckle assembly (seat belts)

    NHTSA 04V189000 Reported 331 vehicles potentially affected GENERAL MOTORS CORP.

    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.

    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.

  6. Service brakes, hydraulic

    NHTSA 04V045000 Reported 68,875 vehicles potentially affected GENERAL MOTORS CORP.

    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.

    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.

21 owner complaints filed with NHTSA

Owners of the 2004 Chevrolet Express have filed 21 complaints with NHTSA; 1 describe a crash and 2 describe a fire. The average mileage at failure in those reports is 87,912 miles. Complaints peaked in 2005 with 4 filed that year.

Most-reported components

What owners are reporting

“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.”

Owner complaint to NHTSA, March 1, 2022 · Fuel/propulsion system

“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”

Owner complaint to NHTSA, December 30, 2021 · Suspension

Fuel economy and specs

EPA ratings for the 2004 Chevrolet Express Passenger (Express 1500 AWD, Express 1500/2500 2WD, Express Passenger (Bi-fuel), Express Passenger (dedicated CNG)). Ranges cover every tested configuration.

Combined12–15 mpg
City / Highway11–14 / 15–18
FuelCNG, Gasoline or natural gas, Regular
EPA classVans, Passenger Type
Engine6/8 cyl, 4.3/5.3/6 L
TransmissionAutomatic 4-spd

Compare Chevrolet Express model years

Recall and complaint counts for every Chevrolet Express model year in NHTSA's database.

Model yearRecallsComplaints
1995 Chevrolet Express01
1996 Chevrolet Express215
1997 Chevrolet Express129
1998 Chevrolet Express123
1999 Chevrolet Express168
2000 Chevrolet Express184
2001 Chevrolet Express245
2002 Chevrolet Express055
2003 Chevrolet Express1059
2004 Chevrolet Express621
2005 Chevrolet Express823
2006 Chevrolet Express1612
2007 Chevrolet Express417
2008 Chevrolet Express1014
2009 Chevrolet Express710
2010 Chevrolet Express515
2011 Chevrolet Express512
2012 Chevrolet Express613
2013 Chevrolet Express822
2014 Chevrolet Express714
2015 Chevrolet Express38
2016 Chevrolet Express615
2017 Chevrolet Express621
2018 Chevrolet Express611
2019 Chevrolet Express48
2020 Chevrolet Express117
2021 Chevrolet Express213
2023 Chevrolet Express12
2024 Chevrolet Express01
2025 Chevrolet Express40
2026 Chevrolet Express30

Checking a specific 2004 Chevrolet Express

How do I know if my 2004 Chevrolet Express has an open recall?

Enter your 17-character VIN above. The VIN is on the driver's side dashboard (visible through the windshield), the driver's door jamb sticker, and your registration or insurance card. The check runs against NHTSA's live database and tells you which campaigns list your vehicle. 6 campaigns currently list the 2004 Chevrolet Express; your car may already have been repaired under some of them.

Is the recall repair free?

Yes. Under federal law, manufacturers must fix safety recalls at no charge for vehicles up to 15 years old from the date of sale to the first owner. Contact any authorised Chevrolet dealer with your VIN and the NHTSA campaign number (for example 04V045000).

What is the difference between a recall and a complaint?

A recall is a safety campaign filed by the manufacturer or ordered by NHTSA, with a defined defect and remedy. A complaint is a report an owner sent to NHTSA; it is not verified, but patterns of complaints are what trigger NHTSA investigations and, eventually, recalls.

Other Chevrolet models

Source: NHTSA recall and complaint databases and EPA fuel economy data, October 2026. Complaint counts are owner reports to NHTSA, not verified defects. Recall counts are safety campaigns that list this model year; whether a particular car was already repaired depends on its VIN. How this data is compiled.