RoadVitals

2004 Chevrolet Express 1500

Recalls, owner-reported complaints, investigations and safety data

Data refreshed

Owner complaintsComplaints are reports submitted to NHTSA by owners and drivers. NHTSA does not verify most reports before publishing them, and a complaint does not establish that a defect exists. Volume is influenced by how many of a vehicle were sold, how long it has been on the road, and how much attention an issue has received.
12
Latest Jan 20, 2019
Safety recallsA safety recall is issued when a manufacturer or NHTSA determines that a vehicle has a safety-related defect or does not comply with a federal motor vehicle safety standard. Recall repairs are free. Whether a specific vehicle is covered depends on its VIN — a recall listed for a model year does not necessarily apply to every vehicle of that year.
1
Latest May 19, 2006
InvestigationsNHTSA opens an investigation to examine whether a safety defect may exist. An open investigation is not a determination that a defect exists, and many investigations close without a recall. Investigations can, however, lead to one.
0
Crash or fire reportedComplaints whose submitter recorded that a crash or a fire occurred. These are the reporter's own answers on the NHTSA form, not verified findings.
2
1 injuries, 0 deaths reported

Overview

Our database contains 12 NHTSA owner-reported complaints for the 2004 Chevrolet Express 1500, most frequently naming the brakes, fuel system and visibility categories. 1 safety recall has been issued covering this model year; and 90 manufacturer communications are on file.

Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.

What owners report

Complaints grouped by the component NHTSA recorded

  • Brakes320.0%
  • Fuel system320.0%
  • Visibility213.3%
  • Engine213.3%
  • Airbags213.3%
  • Body & structure16.7%
  • Electrical16.7%
  • Tires & wheels16.7%

Percentages are of component mentions. A single complaint can name more than one component, so these do not sum to the total complaint count.

Safety recalls

1 campaign cover this model year

Recalls apply to specific vehicles, not to every vehicle of a model year. Check your VIN with NHTSA or your manufacturer's dealer to confirm whether a recall affects your vehicle.

Check a VIN on NHTSA.gov

FUEL SYSTEM, GASOLINE

May 19, 2006
88,303 units potentially affected
The defect: CERTAIN REPLACEMENT FUEL FILTERS, FRAM BRAND NAME P/N G3727, WITH DATE CODES X52911 THROUGH X60801 SEQUENTIALLY OR X600141 AND A MEXICO COUNTRY OR ORIGIN MARKING ON THE FUEL FILTER HOUSING MANUFACTURED FROM OCTOBER 18, 2005, THROUGH MARCH 21, 2006, SOLD FOR USE ON THE VEHICLES LISTED ABOVE AND ON CERTAIN SCHOOL BUSES. (TO SEE THE SCHOOL BUS ENGINE SIZES, CLICK ON "DOCUMENT SEARCH" AND THEN "BUS APPLICATIONS"). THE CONNECTOR ON THE FUEL FILTER WAS NOT MANUFACTURED TO HONEYWELL'S SPECIFICATION. AS A RESULT, THE O-RING MAY NOT SEAT CORRECTLY ON THE FUEL LINE.
The risk: THIS CONDITION MAY CAUSE AN INADEQUATE SEAL AT THE CONNECTION, POTENTIALLY LEADING TO A FUEL LEAK. IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.
The remedy: HONEYWELL WILL NOTIFY OWNERS AND REPLACE THE FUEL FILTERS FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 18, 2006. OWNERS MAY CONTACT FRAM CUSTOMER SERVICE AT 1-800-890-2075 (OPTION 1).
HONEYWELL INTERNATIONAL, INC.View on NHTSA.gov

Recent owner complaints

Reports submitted to NHTSA, shown in the owner's own words

Fuel system
Filed Jan 20, 2019

MY 2004 CUTAWAY CHEVY SOLD AS A 2005 FOUR WINDS HAS THE EXACT PROBLEM FOR THIS RECALL. RECALL NUMBER 12V388000 RECALL DATE 08/08/2012 COMPONENT FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP SUMMARY 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. CONSEQUENCE SIGNIFICANT CORROSION MAY ALLOW FUEL TO LEAK DURING REFUELING, AND IN THE PRESENCE OF AN IGNITION SOURCE; THERE IS AN INCREASED RISK OF FIRE. WHAT OWNERS SHOULD DO 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. THE EXPRESS 1500 I OWN IS CURRENTLY EXHIBITING THIS EXACT ISSUE, AND ALTHOUGH SOLD IN CA IN 2005, BASE VAN WAS MANUFACTURED IN INDIANA MODIFIED BY THOR MOTORHOMES. THIS STATE IS LISTED IN THE RECALL ABOVE. I'M AFRAID TO DRIVE IT, CAN'T AFFORD TO FIX THE ISSUE BEING DISABLED VET ON SMALL SSDI INCOME. IVE THE FEELING IT'S THE SAME MODEL RECALLED, BUT OF COURSE CHEVY WILL NOT REPAIR IT BECAUSE IT IS NOT SPECIFICALLY ON RECALL LIST LIKE THE LEFT SIDE CARGO DOOR MODELS THAT ARE BEING REPAIRED BY THE CHEVROLET GM DEALERS? PLEASE HELP

NHTSA ID
11171110
Incident
Dec 3, 2018
Mileage
33,000 mi
Fuel system
Filed Jan 31, 2016

THE FUEL FILLER TUBE LEAKS FUEL, IS CORRODED. AND ALSO THE REAR FUEL TANK STRAP, AT THE TOP OF THE CHASSIS IS ALSO CORRODED, AND THE FUEL TANK IS HANGING DOWN, CAUSING A RISK AND FIRE HAZZARD AS IT IS VERY CLOSE TO THE DRIVESHAFT.

NHTSA ID
10823319
Incident
Jul 5, 2015
Mileage
160,000 mi
AirbagsBody & structureEngine
Filed May 29, 2015
Crash reported1 injury reported

I WAS TRAVELING EAST THRO AN INTERSECTION WHEN A TRUCK ON THE MY RIGHT RAMMED ME IN THE FRONT RIGHT SIDE OF MY CAR.I FELT THE CAR SPIN AND THE TRUCK ENDED UP IN MY RIGHT REAR BUMPER AND WHEN I CAME TO A STOP BOTH AIRBAGS DEPLOYED AND I WAS INJURED AND THE AIRBAGS EXPLODED AND I HAVE EYE DAMAGE TO MY RIGHT EYE AND NECK INJURY AND BACK INJURY. STILL SEEING SPINE DR. AND EYE DR EVERY 6 MONTHS. *TR

NHTSA ID
10722109
Incident
Nov 21, 2013
Mileage
250,000 mi
Fuel system
Filed Aug 22, 2012

TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS. THE CONTACT STATED THAT AFTER REFUELING, FUEL SPEW BACK OUT OF THE FILLER NECK. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO DID NOT OFFER ANY ASSISTANCE SINCE THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER: 12V388000 (FUEL SYSTEM, GASOLINE: STORAGE: TANK ASSEMBLY: FILLER PIPE AND CAP). THE FAILURE AND CURRENT MILEAGE WAS 114,000. UPDATED 10/16/12*LJ THE CONSUMER STATED THE FUEL FILLER NECK CORRODED UPDATED 10/19/2012 *JS

NHTSA ID
10471862
Incident
Aug 20, 2012
Mileage
114,000 mi
Tires & wheels
Filed May 17, 2011

WE PURCHASED A COMPLETE SET OF GENERAL GRABBER HTS 235/75R16 FOR OUR CHEVY EXPRESS VAN AT DUNN TIRE ON 11/15/08. THEY WERE SUPPOSED TO HAVE A 60K WARRANTY. WE WENT IN FOR THE REQUIRED ROTATIONS AND NOTED THAT THE TREAD DIDN'T SEEM TO BE WEARING WELL. AT THE 20K MILE ROTATION IN JANUARY OF 2011, DUNN TIRE ACKNOWLEDGED THAT THE TIRES WERE NOT PERFORMING AS ADVERTISED AND TOLD US THAT THEY WOULD LIKELY NEED TO ADJUST THE TIRES ON A PRO-RATA BASIS AT THE NEXT ROTATION AT 25K MILES. IT IS OUR BELIEF THAT THE TIRES ARE DEFECTIVE IN SOME WAY. THE ORIGINAL TIRES ON OUR VAN LIVED UP TO THEIR 40K WARRANTY AND WE REPLACED WITH THESE GRABBER HTS TIRES AT 39747 MILES. OUR DRIVING HABITS ARE CONSERVATIVE AND WE HAVE NEVER HAD TO REPLACE TIRES AHEAD OF THE WARRANTY PERIOD. THE TREAD WAS SO BAD ON THESE GRABBER HTS TIRES THAT WE WERE UNABLE TO DRIVE OUR VAN ON SNOWY ROADS DURING THIS PAST WINTER. WE ALSO WERE CONCERNED ABOUT HYDROPLANING ON THE EXPRESSWAY WHEN WE DROVE THE VAN THROUGH HEAVY RAINS THIS PAST WEEKEND WHEN WE DROPPED OFF OUR DAUGHTER AT COLLEGE. WE BELIEVE THESE TIRES ARE HAZARDOUS AND THAT AN INVESTIGATION SHOULD BE INITIATED. IT'S INCONCEIVABLE THAT WE WOULD ONLY GET 25K MILES OUT OF A 60K TIRES. WE FEEL CHEATED AND REALLY DO NOT WANT ANOTHER SET OF GENERAL TIRES ON A PRO-RATA BASIS. *TR

NHTSA ID
10401305
Incident
Jan 11, 2011
Brakes
Filed Jan 30, 2010

2004 CHEVY EXPRESS 1500. *TR

NHTSA ID
10303324
Incident
Nov 5, 2007
Mileage
18,580 mi
Brakes
Filed Mar 30, 2009

ABS ENGAGES AT SLOW SPEED, AT TAIL END OF BRAKING, EVEN ON DRY SURFACES. THIS HAS BEEN GOING ON FOR AT LEAST EIGHT MONTHS. STARTED SOMETIME IN EARLY SUMMER/LATE SPRING 2008. *TR

NHTSA ID
10263589
Incident
Mar 28, 2009
Mileage
35,000 mi
Airbags
Filed Mar 19, 2009

THE PASSENGER SIDE AIRBAG EMPLOYED WHEN THE VEHICLE WAS PARKED INSIDE THE SHOP. THE VEHICLE IS AVAILABLE FOR INSPECTION AT STANLEY CHEVROLET CELINA TX 972-382-3000 CONTACT GARY WERNER SERVICE MANAGER. THE VEHICLE OWNER IS RICK DIETEL OF AMERSOL INC. 214-503-9977. *TR

NHTSA ID
10262412
Incident
Mar 13, 2009
Mileage
91,048 mi

Manufacturer communications

A bulletin sent by a manufacturer to its dealers. Not a recall, and repairs are not necessarily free.

PIP5601C

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

03-06-01-023I

ENGINE

This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.

03-06-01-023H

ENGINE

This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.

PIT3271P

This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed for the vehicle in question and its applications. Technician should not use the information that is provided by the antilock braking system tire size selection.

General Communication

ELECTRICAL SYSTEM

Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected modules (with some exceptions). The updating of modules is completed in parallel instead of the technician needing to update one module at a time. This allows a more streamlined approach for dealers and customers.

24-NA-141

POWER TRAIN

GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the dealers to be more careful not to damage the transmissions during removal and to package the core properly for return.

Manufacturers file copies of the bulletins they send to dealers with NHTSA. These often describe diagnostic or repair procedures for a known condition. They are not recalls: repairs described in a bulletin are usually only free if the vehicle is still under warranty or the manufacturer has extended coverage.

Compare model years

Complaint and recall counts across every year of this model

Chevrolet Express 1500 by model year
YearComplaintsRecallsInvestigationsIssue Index
2014100046.9
2013000
2012200
2011320
2010400
2009500
2008900
2007510
2006500
2005101043.9
2004Viewing121041.2
2003181147.7
2002101030.1
2001510
2000610
1999410
1998000
1997000
1996400

Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers. Older model years have had longer for reports to accumulate.