Representative 2002 model. Photo: SsmIntrigue, Wikimedia Commons, CC BY-SA 4.0

Recalls & complaints · NHTSA data

2004 Chevrolet Express recalls

Every recall campaign and owner complaint NHTSA has on file for the 2004 model year. Not every vehicle is affected by every campaign: check a specific car by VIN below.

Recall campaigns: 10
Park-it warnings: 0
Complaints: 57
Latest campaign: Apr 6, 2023

Recall summary by component10

NHTSA Recalls API · cached ≤24 h

Component	Campaigns	Latest	Campaign IDs
Fuel system, gasoline	2	Aug 8, 2012	12V388000 06E043000
Exterior lighting	2	Apr 7, 2009	09E012000 05V559000
Seat belts	2	Dec 19, 2005	05V558000 04V189000
Service brakes, hydraulic	2	Feb 8, 2005	05V043000 04V045000
Electrical system	1	Apr 6, 2023	23V247000
Power train	1	Jul 6, 2004	04V320000

Safety recalls10

NHTSA Recalls API · cached ≤24 h

0Park-it warnings

0Fixable over the air

Apr 6, 2023Latest campaign


Apr 6, 202323V247000	Electrical system: wiring An overheated electrical circuit increases the risk of a fire. DetailsHide details for campaign 23V247000 What's wrong General Motors, LLC (GM) is recalling certain 2003-2023 Chevrolet Express Cutaway and GMC Savana Cutaway incomplete vehicles equipped with wiring for an optional rear heating, ventilation, and air-conditioning (HVAC) system. When the HVAC blower motor circuit is left unused with exposed connectors and wiring, the circuit can corrode and overheat. Risk An overheated electrical circuit increases the risk of a fire. Remedy Dealers will properly seal the rear HVAC blower motor circuits at the left side B-pillar, free of charge. Owner notification letters were mailed May 2, 2023. Owners may contact Chevrolet customer service at 1-800-222-1020 or GMC customer service at 1-800-462-8782. GMC's number for this recall is N222386050. Filed under Express Cutaway Van Campaign NHTSA 23V247000 · Apr 6, 2023
Aug 8, 201212V388000	Fuel system, gasoline: storage tank assembly Significant corrosion may allow fuel to leak during refueling, and in the presence of an ignition source; there is an increased risk of fire. DetailsHide details for campaign 12V388000 What's wrong 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. Risk 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. Filed under Express Campaign NHTSA 12V388000 · Aug 8, 2012
Apr 7, 200909E012000	Exterior lighting DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH. DetailsHide details for campaign 09E012000 What's wrong SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. 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. Risk DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH. Remedy SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON MAY 11, 2009. OWNERS MAY CONTACT SABERSPORT AT 1-909-598-7589. Filed under Express Campaign NHTSA 09E012000 · Apr 7, 2009
May 19, 200606E043000	Fuel system, gasoline THIS CONDITION MAY CAUSE AN INADEQUATE SEAL AT THE CONNECTION, POTENTIALLY LEADING TO A FUEL LEAK. DetailsHide details for campaign 06E043000 What's wrong 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. 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. 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). Filed under Express 2500 Campaign NHTSA 06E043000 · May 19, 2006
Dec 19, 200505V558000	Seat belts IN THE EVENT OF A CRASH, A SEAT OCCUPANT MAY NOT BE PROPERLY RESTRAINED INCREASING THE RISK OF PERSONAL INJURY. DetailsHide details for campaign 05V558000 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. Risk 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. Filed under Express Campaign NHTSA 05V558000 · Dec 19, 2005
Dec 13, 200505V559000	Exterior lighting FOLLOWING VEHICLES MAY NOT BE FULLY INFORMED OF VEHICLE BRAKING. DetailsHide details for campaign 05V559000 What's wrong 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. Risk 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. Filed under Express 2500 Campaign NHTSA 05V559000 · Dec 13, 2005

Merged from NHTSA model names: Express Cutaway Van, Express, Express 2500. Not every vehicle of a model year is affected by every campaign.

To see whether a recall is still open on your car, enter the VIN at nhtsa.gov/recalls or the Chevrolet recall lookup. Recall repairs are free at a franchised dealer (federal law; see limits).

Owner complaints by component57

NHTSA Complaints API · cached ≤24 h

57Complaints filed

3Involving a crash

4Involving a fire

1Injuries reported

Component	Complaints	%	Crashes	Fires	Injuries
Service brakes	17	30	1	0	0
Hydraulic	11	19	1	0	0
Fuel/propulsion system	6	11	0	0	0
Steering	6	11	0	1	0
Structure	5	9	1	1	1
Fuel system	5	9	0	0	0
Gasoline	5	9	0	0	0
Power train	4	7	0	0	0
Engine and engine cooling	4	7	0	0	0
Seat belts	3	5	0	0	0
Air bags	3	5	2	0	1
Electrical system	3	5	0	1	0
Tires	2	4	0	0	0
Engine	2	4	1	1	1
Visibility	2	4	0	0	0

5 more components with fewer complaints not shown. An owner can tag several components, so percentages add up to more than 100. Complaints are unverified owner reports, de-duplicated by NHTSA ODI number.

Latest reports

Fuel/propulsion system
“NHTSA Campaign Number: 12V388000. I have this problem. A leaking fuel line due to corrosion. I drive in the Cascade MT's of Washington state. my line now leaks excessively on fill up.”
Filed 03/01/2022 · ODI 11454777
Suspension
“This vehicle was sold for use over US highways, as "repairable condition". After going to a mechanic shop, I was advised, because of sever rust the rear leaf spring hangers were completely rusted thru, the rear axle…”
Filed 12/30/2021 · ODI 11445566
Fuel/propulsion system
“My 2004 cutaway chevy sold as a 2005 four winds has the exact problem for this recall.”
Filed 01/20/2019 · ODI 11171110

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2004 Chevrolet Express recall questions

How many recalls does the 2004 Chevrolet Express have?

NHTSA lists 10 safety recall campaigns for the 2004 Chevrolet Express. The most recent, 23V247000 (reported April 6, 2023), concerns electrical system. Not every vehicle is covered by every campaign; check a specific car by VIN.

What are the 2004 Chevrolet Express recalls for?

The largest group is fuel system, gasoline, with 2 campaigns. Others: exterior lighting (2), seat belts (2), service brakes, hydraulic (2). Each campaign below lists the defect, the risk and the free remedy.

What is the most common complaint about the 2004 Chevrolet Express?

Service brakes is the most-reported component, named in 17 complaints out of 57 filed with NHTSA (30%). Across all complaints, owners reported 3 crashs and 4 fires. Complaints are unverified owner reports.

How do I check if a recall is open on my 2004 Chevrolet Express?

Enter the 17-character VIN at nhtsa.gov/recalls or the Chevrolet recall lookup. That shows campaigns still unrepaired on that exact car. Safety recall repairs are free at a franchised Chevrolet dealer.

Check a specific Chevrolet by VIN

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