2004 Chevrolet Express: Recalls, Problems & MPG
Here are the deets on the 2004 Chevrolet Express: 6 recalls, 21 owner complaints and up to 12 mpg combined.
Recalls
6 vehicle recalls from the manufacturer, plus 1 equipment/tire recall that can apply. Repairs are free. Check your VIN to see if one is still open on your car.
Brakes (hydraulic) Vehicle recall #04V045000 · 2004 · 68,875 vehicles
What's 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.
Why it matters: 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…
The 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.
Seat belts Vehicle recall #04V189000 · 2004 · 331 vehicles
What's 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.
Why it matters: The safety belt May not restrain the occupant as intended during a crash, which could result in injury to the occupant.
The 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.
Transmission & drivetrain Vehicle recall #04V320000 · 2004 · 1,792 vehicles
What's 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.
Why it matters: If this were to occur, the vehicle could move in a direction not anticipated by the driver, which could result in a vehicle crash.
The 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.
Brakes (hydraulic) Vehicle recall #05V043000 · 2005 · 77,411 vehicles
What's 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.
Why it matters: 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…
The 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.
Seat belts Vehicle recall #05V558000 · 2005 · 425,593 vehicles
What's wrong: On certain full-size passenger, cargo, or cutaway vans, the front and rear seat belt buckles will not latch or will not unlatch.
Why it matters: In the event of a crash, a seat occupant May not be properly restrained increasing the risk of personal injury.
The 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.
Fuel system Vehicle recall #12V388000 · 2012 · 9,389 vehicles
What's wrong: Water and road contaminants May become trapped in the protective conduit that covers the fuel filler pipe and May cause the pipe to corrode.
Why it matters: Significant corrosion May allow fuel to leak during refueling, and in the presence of an ignition source; there is an increased risk of fire.
The 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.
1 aftermarket equipment / tire recall replacement parts sold to fit this car, not the car itself
Exterior lights Equipment recall #09E012000 · 2009 · 16,270 vehicles
What's wrong: These headlamps fail to conform to the requirements of Federal Motor Vehicle Safety Standard no. 108, "lamps, reflective devices, and associated equipment." these lamps do not contain the required amber side reflectors.
Why it matters: Decreased lighting visibility May result in a vehicle crash.
The fix: Sabersport will notify owners and offer a full refund for the noncompliant combination lamps. The safety recall began on May 11, 2009.
Most-reported problems
Owner complaints filed with NHTSA, by component. One complaint can list several components. 2 mention a fire, 0 injuries and 0 deaths were reported.
What owners describe
- Seat belts (3): no single recurring theme in the descriptions.
- Brakes (hydraulic) (3): the most common themes are rust / corrosion (2).
- Brakes (3): no single recurring theme in the descriptions.
- Steering (2): no single recurring theme in the descriptions.
The 2004 Chevrolet Express has 21 owner complaints, ranking #10 of 31 Express model years for complaints (about average; the typical year has 21). Complaints peaked in 2005 (4 filed that year). The typical problem showed up when the car was about 8 years old, at a median of 87,000 miles. Neighboring years: 2003 (59 complaints, 10 recalls), 2005 (23 complaints, 8 recalls).
Engines & fuel economy (EPA)
| Engine | Transmission | Drive | City | Hwy | Comb. | Fuel |
|---|---|---|---|---|---|---|
| 6.0 L 8-cyl | Automatic 4-spd | Rear-Wheel Drive | 11 | 15 | 12 | Gasoline or natural gas |
| 6.0 L 8-cyl | Automatic 4-spd | Rear-Wheel Drive | 11 | 15 | 12 | CNG |
Want the full repair deets? Get the factory manual.
Recall and complaint data tells you what goes wrong. A service manual tells you how to fix it: torque specs, wiring diagrams, fluid capacities and step-by-step procedures for the 2004 Chevrolet Express.
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FAQ
Does the 2004 Chevrolet Express have any recalls?
Yes. NHTSA lists 6 vehicle recalls for the 2004 Chevrolet Express, plus 1 equipment or tire recalls that can apply. Recall repairs are free at any dealer, no matter how old the car is. Check your VIN at nhtsa.gov/recalls.
What are the most common 2004 Chevrolet Express problems?
Owners have filed 21 complaints with NHTSA. The most-reported areas are seat belts (3), brakes (hydraulic) (3), brakes (3).
What gas mileage does the 2004 Chevrolet Express get?
EPA ratings run up to 12 mpg combined (6.0 L, Automatic 4-spd), across 2 engine and transmission combos.
Where can I get a 2004 Chevrolet Express repair manual?
eManualOnline sells downloadable manuals, Mitchell 1 DIY and ALLDATAdiy sell online access to factory repair data, and Haynes sells printed guides and online access. Pick a download if you want to keep it, or a subscription for wiring diagrams and TSBs.