2004 Chevrolet Express recalls and problems
The 2004 Chevrolet Express has 6 safety recalls and 21 owner complaints filed with NHTSA. Recall repairs are free at any Chevrolet dealer.
Recalls may cover only some 2004 Chevrolet Express vehicles. Check your VIN at NHTSA ↗ to see open recalls for your exact car.
2004 Chevrolet Express recalls
Recall 12V-388: Fuel System, Gasoline
Problem: 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.
Fix: 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 05V-558: Seat Belts
Problem: 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.
Fix: 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 05V-043: Service Brakes, Hydraulic
Problem: 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.
Fix: 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 04V-320: Power Train
Problem: 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.
Fix: 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 04V-189: Seat Belts
Problem: 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.
Fix: 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 04V-045: Service Brakes, Hydraulic
Problem: 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.
Fix: 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.
2004 Chevrolet Express problems reported by owners
| Problem area | Reports | |
|---|---|---|
| Seat Belts | 3 | |
| Service Brakes, Hydraulic | 3 | |
| Service Brakes | 3 | |
| Steering | 2 | |
| Fuel System, Gasoline | 2 | |
| Electrical System | 2 | |
| Structure | 2 | |
| Fuel/Propulsion System | 2 | |
| Engine and Engine Cooling | 1 | |
| Air Bags | 1 | |
| Parking Brake | 1 | |
| Power Train | 1 |
Most reported parts
- Fuel System, Gasoline › Delivery › Fuel Pump — 2
- Structure › Body — 2
- Steering › Linkages › Knuckle › Spindle › Arm — 1
- Engine and Engine Cooling › Engine — 1
- Electrical System › Alternator/Generator/Regulator — 1
- Electrical System › 12v/24v/48v Battery — 1
- Seat Belts › Front › Buckle Assembly — 1
- Power Train › Automatic Transmission › Lever and Linkage › Column Shift — 1
Typical mileage at the time of the problem: 109,000 miles (median of owner reports).
Problems that are not covered by a recall are paid repairs; labor rates follow local mechanic pay — see what auto mechanics earn in each state.
Recent 2004 Chevrolet Express complaints
Owner reports filed with NHTSA, as written (personal details removed). Complaints are not verified by NHTSA.
Other Chevrolet Express years
Frequently asked questions
Does the 2004 Chevrolet Express have any recalls?
Yes — NHTSA lists 6 recalls for the 2004 Chevrolet Express: 12V-388 (fuel system, gasoline), 05V-558 (seat belts), 05V-043 (service brakes, hydraulic), 04V-320 (power train), 04V-189 (seat belts) and more. Not every vehicle is affected, so check your VIN at nhtsa.gov/recalls.
What is the most common problem with the 2004 Chevrolet Express?
Owners report seat belts problems most often (3 reports), followed by service brakes, hydraulic (3). The typical mileage when problems were reported is about 109,000 miles.
Are Chevrolet recall repairs free?
Yes. Safety recall repairs are free at authorized Chevrolet dealers, whether you are the first owner or bought the car used.