2004 CHEVROLET EXPRESS 3500 Problems & Recalls
Detailed safety information and owner complaints
Problem Breakdown
Compare to Other Years
Common Problems
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 TH...
Mileage: 43,997
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 CRACK...
Mileage: 120,187
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.
Mileage: 25,000
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.
Mileage: 25,000
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 ...
Mileage: 128,000
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 INC...
Mileage: 130,000
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 O...
Mileage: 200,000
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 FAILUR...
Mileage: 39,000
GASOLINE AND GASOLINE VAPOR WAS ESCAPING FROM THE FUEL FILLER PIPE LEADING TO THE FUEL TANK ON A 2004 CHEVY EXPRESS VAN 3500 SERIES. THE FILER PIPE WAS RUSTED THROUGH. THERE WAS A SEAM ON THE PIPE WHERE THE RUST THROUGH OCCURRED. GASOLINE WAS DRIPPING FROM THIS HOLE DURING GASOLINE FILL UP AND ...
Mileage: 170,000
DANGEROUS AS GAS TANK RUSTED THROUGH ON TOP AND LEFT SIDE AFTER ONLY ROUGLY 100,000 MILES. *TR
Mileage: 104,000
TL*THE CONTACT OWNS A 2004 CHEVROLET CARGO EXPRESS VAN 3500. WHILE DRIVING 45 MPH HE HAD ATTEMPTED TO BRAKE AND NOTICED THAT THE BRAKE PEDAL EXTENDED TO THE FLOOR AND THE VEHICLE COULD ONLY BE STOPPED BY MANUALLY DOWN SHIFTING THE GEARS. THE DEALER INFORMED THE CONTACT THAT THE COOLANT LINE RUBBED T...
Mileage: 66,445
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 WA...
Mileage: 50,000
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 WA...
Mileage: 50,000
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 RE...
Mileage: 60,000
2004 CHEVY EXPRESS WITH BROKEN STEERING IDLER. CONSUMER IS PLEASED BECAUSE THE DEALER FIXED THE PROBLEM. *KB **NAR**
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...
TL*THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 3500. WHILE DRIVING 5-10 MPH, THE CONTACT HEARD A CLUNKING NOISE AND THE STEERING BECAME DIFFICULT. THE DEALER STATED THAT THE STEERING IDLER ARM WAS CRACKED. THE MANUFACTURER DENIED THE REPAIR AS PART OF RECALL NUMBER 07103 BECAUSE THE CRACK ON THE ID...
Mileage: 39,000
DT*: THE CONTACT STATED WHILE DRIVING ON THE HIGHWAY AT VARIOUS SPEEDS FOR AN EXTENDED PERIOD OF TIME WITH BRAKES DEPRESSED, THE STEERING WHEEL VIOLENTLY SHOOK. THE VEHICLE WAS INSPECTED BY A DEALER WHO TURNED THE BRAKE ROTORS. AFTERWARDS, THE PROBLEM PERSISTED. THE VEHICLE WAS TAKEN BACK TO THE...
Mileage: 9,800