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2004 Chevrolet Express 3500

Owner reports · Recalls · Investigations

Limited comparison data

There is not enough comparable history to draw a useful model-year comparison.

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How this year compares

Owner complaints by model year

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Counts vary with age, sales and reporting. They are not failure rates.

What owners reported most

All reported categories

Tap a category to read its complaints. One report may name several components.

When problems were reported

Mileage at the reported incident

Limited mileage data: 14 of 16 reports include usable mileage. There isn’t enough coverage to show a useful chart.

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Steering. Review the 4 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Fuel System, Gasoline. Review the 3 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes, Hydraulic. Review the 3 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

0 crash reports1 fire reports0 injury reports

What owners actually said

16 reports
43,997 miles · Apr 11, 2016
Service Brakes

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…

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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 ODI #10854900

120,187 miles · Sep 4, 2015
Tires

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. I…

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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 ODI #10761661

25,000 miles · May 28, 2014
Structure

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 ODI #10594475

128,000 miles · May 23, 2014
Service Brakes

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 T…

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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 ODI #10593709

130,000 miles · Nov 21, 2013
Fuel/propulsion System

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 VEHIC…

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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 ODI #10553177

200,000 miles · Jul 14, 2013
SteeringFire

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 TH…

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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 ODI #10524779

39,000 miles · May 3, 2013
Fuel System, Gasoline

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 …

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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 ODI #10510492

170,000 miles · Jul 2, 2012
Fuel System, Gasoline

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 VAPORS WERE ENTERING THE PASSE…

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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 VAPORS WERE ENTERING THE PASSENGER COMPARTMENT. WE HAD IT REPLACED BY A CERTIFIED MECHANIC BECAUSE IT WAS A POTENTIALLY EXPLOSIVE SITUATION, ACCORDING TO THE MECHANIC. THIS WAS REPORTED TO GM. THERE WAS NO RECALL ON THIS PART, SO GM REFUSED TO PAY FOR THE COST OF THE REPLACEMENT PART AND LABOR. THE REPLACEMENT PART IS NOW PLASTIC. SO GM MUST HAVE RECOGNIZED THE PROBLEM (BUT FAILED TO RECALL) AND CHANGED THE PIPE TO A RUST-PROOF MATERIAL. *JS

NHTSA ODI #10463960

104,000 miles · Apr 10, 2012
Fuel System, Gasoline

DANGEROUS AS GAS TANK RUSTED THROUGH ON TOP AND LEFT SIDE AFTER ONLY ROUGLY 100,000 MILES. *TR

NHTSA ODI #10454780

66,445 miles · Aug 20, 2009
Service Brakes, Hydraulic

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 THROUGH TO THE BRAKE LINE. THER…

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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 THROUGH TO THE BRAKE LINE. THERE WAS A BURNING SMELL PRIOR TO THE FAILURE IN THE FRONT AXLE AREA OF THE VEHICLE. THE CURRENT AND FAILURE MILEAGES WERE 66445.

NHTSA ODI #10281151

Official recalls

0

No recalls in this snapshot.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

0

No exact-year investigations in this snapshot.