RoadVitals

2004 Chevrolet Express 3500 Problems

Owner-reported complaints filed with NHTSA, grouped by component

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.
16
Latest Apr 11, 2016
Components namedHow many of our component categories appear on at least one report for this model year. One report can name several.
6
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.
1

What this page shows

Everything below is an owner-reported complaint submitted to NHTSA about the 2004 Chevrolet Express 3500, grouped by the component NHTSA recorded on the report. These are not confirmed defects, and they are not recalls. NHTSA does not verify most reports before publishing them, and a category with more reports in it is not evidence that a part is defective.

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

Reports by component

Ranked by how many owner reports name each component category

  • Brakes529.4%
  • Fuel system423.5%
  • Steering423.5%
  • Body & structure211.8%
  • Driver assistance15.9%
  • Tires & wheels15.9%

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

Each component in detail

What the reports in each category say, in the owners' own words

Brakes

Reports naming service brakes, the antilock braking system, brake hoses, master cylinders or the parking brake.

5
reports

From owner reports, verbatim

2004 CHEVROLET EXPRESS COLLINS SCHOOL BUS WHILE DRIVING AT 15 MPH ON AN INCLINED RURAL COUNTRY ROAD ATTEMPTING TO BRAKE NOTICED PEDAL EXTENDED TO THE FLOOR AND WAS STOPPED BY FURTHER DOWN SHIFTING AND APPLYING EMERGENCY BRAKE. INFORMED BY REPAIR SHOP THE RIGHT FRONT HYDRAULIC LINE RUBBED THROUGH THE METAL BRAKE LINE CAUSING THE FAILURE. FAILURE MILEAGE 43,997.

NHTSA ID 10854900 · filed Apr 11, 2016

TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 3500. THE CONTACT STATED WHILE DRIVING DOWN A MOUNTAIN ROAD APPROXIMATELY 45 MPH THE BRAKE PEDAL WAS DEPRESSED AND THE VEHICLE BEGAN TO VIBRATE EXCESSIVELY AND THE BRAKE DISCS OVERHEATED. THE FAILURE WAS NOT DIAGNOSED NOR WAS THE VEHICLE REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE DEFECT. THE APPROXIMATE FAILURE MILEAGE WAS 128,000. UPDATED 08/11/14*LJ UPDATED 08/18/2014 *JS

NHTSA ID 10593709 · filed May 23, 2014

Too few reports in this category for a page of its own — they appear in the full complaint list.

Fuel system

Reports naming fuel storage or delivery — tanks, pumps, lines, injectors and fuel leaks.

4
reports

From owner reports, verbatim

TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 3500. THE CONTACT STATED THE FUEL FILLER NECK TUBE WAS CORRODED, CAUSING FUEL TO LEAK WHEN REFUELING THE VEHICLE. THE CONTACT REFERENCED NHTSA CAMPAIGN NUMBER: 12V388000 (FUEL SYSTEM, GASOLINE) BUT WAS ADVISED BY THE MANUFACTURER THAT THE VIN WAS NOT INCLUDED IN THE RECALL. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 130,000.

NHTSA ID 10553177 · filed Nov 21, 2013

TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 3500. THE CONTACT STATED THAT THE FUEL TANK PIPE WAS SEVERELY RUSTED AND WAS LEAKING. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSIS. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE DEFECT. THE APPROXIMATE FAILURE MILEAGE WAS 39,000. THE VIN WAS UNAVAILABLE.

NHTSA ID 10510492 · filed May 3, 2013

Too few reports in this category for a page of its own — they appear in the full complaint list.

Steering

Reports naming the steering system — racks, columns, power-steering assist and steering linkage.

4
reports

From owner reports, verbatim

ON JUNE 08, 2013 MY HUSBAND HAD PARKED THE VAN ALONG SIDE THE ROAD - HE WAS OUT OF IT WORKING. THE VEHICLE WAS NOT RUNNING - WHEN A COWORKER NOTICED SMOKE COMING FROM THE VAN. THE COWORKER RAN OVER TO THE VAN AND SEEN THAT THE FIRE WAS IN THE STEERING COLUMN. WITHIN MINUTES THE ENTIRE VAN WAS ON FIRE. MY CONCERN IS THAT THIS VAN HAD BEEN HAVING ISSUES WITH SOMETHING SECURITY. ALL OF THE GAUGES WOULD SHUT DOWN AND IT WOULD DISPLAY "SECURITY " ON THE DASH. I PERSONALLY HAD CONTACTED OUR LOCAL CHEVY DEALER TO INQUIRE ABOUT THIS PROBLEM AND HOW TO TAKE CARE OF IT. THE LOCAL DEALER SUGGESTED A NEW KEY MADE AT THE DEALERSHIP USING THE VIN NUMBERS. THIS MADE NO DIFFERENCE AS IT HAPPENED AGAIN. THIS TIME MY HUSBAND WENT TO A DEALERSHIP IN NORWALK, OHIO INQUIRING ABOUT THE PROBLEM - THEY HAD NO IDEA WHAT THE SOLUTION WAS EITHER. MY CONCERN IS THAT THE DEALERSHIPS HAVE NO IDEA WHAT THE "SECURITY" IS OR HOW TO FIX IT......ALSO I AM WONDERING IF THIS "SECURITY" ISSUE IS THE REASON THAT I LOST MY VAN TO THE FIRE ON JUNE 08, 2013. I CONTACTED GM BUT THEY BLEW ME OFF SAYING I HAD OWNED THE VEHICLE TOO LONG TO GET ANY MONEY FOR MY LOSS. THESE VANS ARE DESIGNED TO CARRY LOTS OF PEOPLE AND IF MY FAMILY HAD BEEN IN THIS VEHICLE AT THE TIME OF THE FIRE THERE WOULD NOT HAVE BEEN ENOUGH TIME TO GET EVERYONE OUT SAFELY AND THAT WORRIES ME GREATLY. *TR

NHTSA ID 10524779 · filed Jul 14, 2013

TL*THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 3500. WHILE DRIVING APPROXIMATELY 35 MPH, THE VEHICLE SUDDENLY LOST POWER STEERING AND BRAKING ABILITY. SHE LOST CONTROL OF THE VEHICLE. SHE SHIFTED INTO A LOWER GEAR AND WAS ABLE TO COMPLETELY STOP THE VEHICLE. THE CONTACT WAS ABLE TO TURN OFF AND RESTART THE VEHICLE. THE VEHICLE WAS TAKEN TO NUMEROUS DEALERS AND SHOPS, BUT THEY ALL CONFIRMED THAT THE HYDRO BOOST FAILED. THERE WAS A RECALL, IN WHICH THE VEHICLE WAS NOT INCLUDED. NO RECALL COULD BE FOUND FOR THE CHEVROLET EXPRESS 3500 ON THE NHTSA WEBSITE. THE CONTACT BELIEVED THAT IF THE FAILURE WAS COMMON, A RECALL SHOULD BE ISSUED. THE CURRENT AND FAILURE MILEAGES WERE 60,000.

NHTSA ID 10250646 · filed Dec 3, 2008

Too few reports in this category for a page of its own — they appear in the full complaint list.

Body & structure

Reports naming the vehicle structure, frame, body panels, doors, hood and trim.

2
reports

From owner reports, verbatim

TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 3500. THE CONTACT STATED THAT THE PASSENGER AND DRIVER SIDE DOOR HINGES WERE FRACTURED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 25,000.

NHTSA ID 10594475 · filed May 28, 2014

FAULTY HINGE PINS ON SIDE DOORS OF 2004 CHEVY 3500 EXPRESS VAN CAUSE SEVERE BINDING OF HINGES. THIS COULD CAUSE EXIT DIFFICULTY FOR CHILD OR ELDERLY TRYING TO EXIT IN CASE OF ACCIDENT OR EMERGENCY. IT IS A PROBLEM WITH MULTIPLE YEARS AND PINS HAVE BEEN REDESIGNED. CHEVY WILL ONLY REPAIR AT CUSTOMERS EXPENSE. THIS IS NOT FROM DAMAGE OR NEGLECT. I HAVE TRIED TO LUBRICATE WITH NO SUCCESS. *JB

NHTSA ID 10205561 · filed Oct 13, 2007

Too few reports in this category for a page of its own — they appear in the full complaint list.

Driver assistance

Reports naming forward-collision avoidance, lane keeping, back-over prevention, cruise control and related electronic driver-assistance systems.

1
report

From owner reports, verbatim

THE BRAKES ON MY 2004 CHEVY EXPRESS 3500 ACTIVATE WITHOUT WARNING, STOPPING THE VEHICLE IN TRAFFIC. A WARNING LIGHT INDICATED A FAILURE OF THE STABILITY CONTROL SYSTEM. FAULT CODE C0196 WAS RECORDED. MY DEALER REPLACED THE ELECTRONIC BRAKE CONTROL MODULE, BUT THE PROBLEM CONTINUES TO OCCUR. I WAS ALMOST REAR-ENDED WHEN THE VEHICLE STOPPED WITHOUT WARNING IN TRAFFIC. *TR

NHTSA ID 10275040 · filed Jun 26, 2009

Too few reports in this category for a page of its own — they appear in the full complaint list.

Tires & wheels

Reports naming tires, wheels, hubs, or the tire-pressure monitoring system.

1
report

From owner reports, verbatim

TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 3500 EQUIPPED WITH TOYO OPEN COUNTRY H/T TUFF DUTY TIRES, SIZE: LT245/75/R16 TIRES. WHILE DRIVING 65 MPH, THE CONTACT HEARD A LOUD NOISE AND THE REAR DRIVER SIDE TIRE BLEW OUT. THE VEHICLE WAS TOWED TO A DEALER WHO DIAGNOSED THAT ALL FOUR TIRES HAD CRACKS AND NEEDED TO BE REPLACED. IN ADDITION, MULTIPLE PARTS NEEDED TO BE REPLACED. THE TIRES WERE REPLACED, BUT THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE FAILURE MILEAGE WAS 120,187 AND THE TIRE FAILURE MILEAGE WAS 25,982.

NHTSA ID 10761661 · filed Sep 4, 2015

Too few reports in this category for a page of its own — they appear in the full complaint list.

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.

Elsewhere on this vehicle

Data sources

Data on this page last refreshed .