Recalls (7)
NHTSA lists 7 recall campaigns for the 2004 Chevrolet Express. Check whether yours was repaired with NHTSA's free VIN lookup ↗
Only NHTSA and your automaker know whether your specific car was repaired. PlainVIN shows every recall campaign listed for a model year, with the official text and how many cars have been fixed so far.
Check on NHTSA ↗Listed for 2004 Chevrolet Express. Not checked against your VIN.
Fuel Filler Pipe Corrosion
Fuel system, gasoline · storage · tank assembly · filler pipe and cap
Official NHTSA text
- 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.
- Remedy
- 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.
Repair progress not yet reported9,389 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 12V388000
Listed for 2004 Chevrolet Express. Not checked against your VIN.
SEAT BELT BUCKLES
Seat belts
Official NHTSA text
- Summary
- ON CERTAIN FULL-SIZE PASSENGER, CARGO, OR CUTAWAY VANS, THE FRONT AND REAR SEAT BELT BUCKLES WILL NOT LATCH OR WILL NOT UNLATCH.
- Consequence
- IN THE EVENT OF A CRASH, A SEAT OCCUPANT MAY NOT BE PROPERLY RESTRAINED INCREASING THE RISK OF PERSONAL INJURY.
- Remedy
- 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.
Repair progress not yet reported425,593 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 05V558000
Listed for 2004 Chevrolet Express. Not checked against your VIN.
CENTER HIGH MOUNTED STOP LAMP/FMVSS 108
Exterior lighting
Official NHTSA text
- Summary
- CERTAIN CONVERSION VANS BUILT ON GMC/CHEVROLET CHASSIS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES AND ASSOCIATED EQUIPMENT." THE HOUSING LENS OF THE CENTER HIGH MOUNTED STOP LAMP DOES NOT ALLOW ENOUGH LIGHT TO EMIT FROM THE LAMP.
- Consequence
- FOLLOWING VEHICLES MAY NOT BE FULLY INFORMED OF VEHICLE BRAKING. REAR-END CRASHES AND INJURY TO OCCUPANTS MAY OCCUR.
- Remedy
- QUALITY COACHES IS WORKING WITH AUDIOVOX TO REPLACE THE CENTER HIGH-MOUNTED BRAKE LAMP ASSEMBLY. OWNERS MAY CONTACT QUALITY COACHES AT 1-800-373-6357 OR ASA AT 1-800-274-1886.
Repair progress not yet reported2 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 05V559000
Listed for 2004 Chevrolet Express. Not checked against your VIN.
HYDRO-BOOST/HYDRAULIC BRAKE/BOSCH
Service brakes, hydraulic
Official NHTSA text
- Summary
- 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.
- Consequence
- 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.
- Remedy
- 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.
Repair progress not yet reported77,411 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 05V043000
Listed for 2004 Chevrolet Express. Not checked against your VIN.
GM/TRANSMISSION SHIFT CABLE SEPARATION
Power train · automatic transmission · lever and linkage · column shift
Official NHTSA text
- Summary
- 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.
- Consequence
- IF THIS WERE TO OCCUR, THE VEHICLE COULD MOVE IN A DIRECTION NOT ANTICIPATED BY THE DRIVER, WHICH COULD RESULT IN A VEHICLE CRASH.
- Remedy
- 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.
Repair progress not yet reported1,792 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 04V320000
Listed for 2004 Chevrolet Express. Not checked against your VIN.
GM/FMVSS 209/SEAT BELT BUCKLE ASSEMBLY
Seat belts · front · buckle assembly
Official NHTSA text
- Summary
- 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.
- Consequence
- THE SAFETY BELT MAY NOT RESTRAIN THE OCCUPANT AS INTENDED DURING A CRASH, WHICH COULD RESULT IN INJURY TO THE OCCUPANT.
- Remedy
- 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.
Repair progress not yet reported331 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 04V189000
Listed for 2004 Chevrolet Express. Not checked against your VIN.
GM/FMVSS 135/BRAKE VALVE
Service brakes, hydraulic
Official NHTSA text
- Summary
- 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.
- Consequence
- 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.
- Remedy
- 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.
Repair progress not yet reported68,875 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 04V045000
PlainVIN shows public government records for education. It isn't a vehicle inspection or legal advice. Check your own VIN with NHTSA or your dealer.
Owner complaints (57)
57 complaints filed with NHTSA (owner reports, not verified findings). The service brakes is mentioned most often.
3involved a crash
4involved a fire
1injuries reported
0deaths reported
As reported by owners in their complaints. These are reports, not NHTSA findings.
Most-reported components
| Component | Complaints | % of 57 |
|---|---|---|
| Service brakes | 17 | 29.8% |
| Fuel/propulsion system | 6 | 10.5% |
| Steering | 6 | 10.5% |
| Fuel system | 5 | 8.8% |
| Structure | 5 | 8.8% |
| Engine and engine cooling | 4 | 7% |
| Power train | 4 | 7% |
| Air bags | 3 | 5.3% |
| Electrical system | 3 | 5.3% |
| Seat belts | 3 | 5.3% |
How 2004 compares with other Express years
Best and worst Express years →200096
200163
200269
2003101
200457
200559
200645
200740
200841
200926
| Model year | Complaints | Recall campaigns |
|---|---|---|
| 2000 | 96 | 1 |
| 2001 | 63 | 2 |
| 2002 | 69 | 0 |
| 2003 | 101 | 10 |
| 2004 | 57 | 7 |
| 2005 | 59 | 8 |
| 2006 | 45 | 17 |
| 2007 | 40 | 6 |
| 2008 | 41 | 11 |
| 2009 | 26 | 9 |
This year (2004)Other yearsStill collecting reports
Counts are owner reports, not failure rates. Higher sales years tend to draw more reports. Owners are still filing reports for recent model years, so these counts will grow. Source: NHTSA ODI, retrieved Oct 6, 2026.
Fuel economy: up to 14 mpg combined
14
mpg combined
13
city
17
highway
- EPA annual fuel cost
- $4,800
- CO₂ tailpipe
- 635 g/mi
- EPA class
- Vans, Passenger Type
What it costs you to run
$4,665per year
$389per month
1,071gallons a year
Miles ÷ 14 mpg × $4.354 (EIA US average regular, week of Oct 5, 2026, all taxes included). Source: EPA · EIA.
EPA label estimates from lab tests; your mileage will vary.
Specs by configuration
| Engine · transmission | Drive | City / Hwy / Comb | EPA $/yr | CO₂ g/mi |
|---|---|---|---|---|
| 5.3 L 8-cyl · 4-speed automatic | 4-Wheel or All-Wheel Drive | 13 / 17 / 14 | $4,800 | 635 |
Source: EPA fuel economy data, retrieved Oct 6, 2026. Configurations are listed when EPA and NHTSA records match.
Looking at a 2004 Express for sale?
Print a one-page buyer's checklist: each recall campaign with a box to tick when the seller shows proof of repair, the top complaint areas to inspect, crash stars, MPG, and a link back to this page.
Where to next
2004 Chevrolet Express FAQ
How many recalls does the 2004 Chevrolet Express have?
NHTSA lists 7 recall campaigns: 12V388000 (fuel system), 05V558000 (seat belt), 05V559000 (lighting), 05V043000 (brake), 04V320000 (power train), 04V189000 (seat belt), 04V045000 (brake). Use NHTSA's VIN lookup to see whether a specific car was repaired.
What are the most common 2004 Chevrolet Express problems?
Owners filed 57 complaints with NHTSA. Service brakes (17), Fuel/propulsion system (6), Steering (6) are mentioned most. These are owner reports, not verified findings.
What mpg does the 2004 Chevrolet Express get?
EPA rates the 5.3 L 8-cyl · 4-speed automatic version at 13 city, 17 highway and 14 combined mpg.
How does the 2004 Express compare with other years?
Among the 2000–2009 Chevrolet Express model years at least five years old, the 2009 drew the fewest complaints (26) and the 2003 the most (101). The 2004 drew 57. Counts are owner reports, not failure rates.
How this page was madeSources, processing, limits, review and changes
Data sources
- NHTSA recalls by vehicle
Retrieved Oct 6, 2026 - US DOT recall completion rates (data.transportation.gov)
Retrieved Oct 6, 2026 - NHTSA ODI owner complaints
Retrieved Oct 6, 2026 - NHTSA NCAP 5-Star Safety Ratings
Retrieved Oct 6, 2026 - EPA fuel economy data (licence confirmation pending)
Retrieved Oct 6, 2026 - EIA weekly retail gasoline prices
Weekly, all taxes included
Processing
- Complaints are counted per component. One complaint can list several, so component totals add up to more than the total.
- Fuel cost = miles per year ÷ EPA combined mpg × EIA weekly price for your region.
Limitations
- Complaint counts are owner reports, not verified findings or failure rates. There is no sales denominator.
- Recall campaigns are listed for the model year. Only NHTSA and the automaker know whether a specific car was repaired.
- Recent model years are still collecting reports.
Review
Data compiled automatically from the official files listed here.
Changelog
- 2026-10-06 Data refreshed from the official files.
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