Does the 2004 Chevrolet Express 2500 have any recalls?

Yes. NHTSA lists 1 recall for the 2004 Chevrolet Express 2500, the most recent reported on December 13, 2005 (Exterior lighting). Check a specific car by its VIN at nhtsa.gov/recalls.

What are the most common problems with the 2004 Chevrolet Express 2500?

Owners have filed 8 complaints with NHTSA. The most frequently reported area is power train (3 complaints), followed by engine and engine cooling (2).

How many 2004 Chevrolet Express 2500 complaints mention a crash or fire?

1 of 8 complaints report a crash and 0 a fire; 0 injuries were reported in total. Complaints are unverified reports from owners.

2004 Chevrolet Express 2500 recalls and problems

1 recall and 8 owner complaints on file with NHTSA for the 2004 Chevrolet Express 2500.

recalls

owner complaints

complaints mentioning a crash

mentioning a fire

Recalls apply to specific production ranges. To see whether a particular car still has an open recall, enter its VIN at nhtsa.gov/recalls. Repairs for safety recalls are free at authorised dealers.

2004 Chevrolet Express 2500 recalls

Exterior lighting

NHTSA campaign 05V559000 · reported December 13, 2005 · QUALITY COACHES INC. · 2 vehicles potentially affected

The problem: 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.
The risk: Following vehicles may not be fully informed of vehicle braking. Rear-end crashes and injury to occupants may occur.
The fix: 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.

Most reported problems

Areas named in owner complaints to NHTSA. One complaint can name several areas.

Power train3
Engine and engine cooling2
Service brakes, hydraulic2
Electrical system1
Equipment1
Service brakes1

What owners report

Recent complaints filed with NHTSA, shortened. These are unverified accounts from owners, not findings.

Oct 5, 2016 · Service brakes · 115,000 miles
TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 2500. THE CONTACT STATED THAT WHEN THE BRAKES WERE APPLIED, THE VEHICLE SHOOK VIOLENTLY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE THE BRAKE PADS AND ROTORS WERE REPLACED; HOWEVER, THE FAILURE CONTINUED. THE CONTACT HAD TO APPLY EXTREME FORCE TO THE BRAKE…

Aug 2, 2013 · Power train · 119,000 miles
TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 2500. THE CONTACT STATED WHENEVER AT AN IDLE A LOUD METAL TO METAL NOISE WOULD EMIT CONTINUOUSLY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC ON TWO SEPARATE OCCASIONS WHERE THE CRACKED FLYWHEEL WAS REPLACED EACH TIME. THE MANUFACTURER WAS NOT NOTIFIED OF THE PROBLEM…

Feb 6, 2012 · Engine and engine cooling · 15,500 miles
AS I ATTEMPTED TO SPEED UP IN TRAFFIC, I HEARD A NOISE AND THE VEHICLE SUDDENLY SLOWED DOWN. I WAS ABLE TO GET IT OFF THE HIGHWAY ON TO A SIDE ROAD. ONCE THERE, IT WOULD NOT START. ON CLOSER INSPECTION, I SAW THAT THE BELT HAD COME APART AND OFF THE PULLEY'S. I HAD THE VAN TOWED TO MY HOME AND SUBSEQUENTLY…

Jun 14, 2010 · Engine and engine cooling · 103,000 miles
MYSTERIOUS COOLANT LEAK. RESERVOIR IS LOW AND NEEDS REFILLING OFTEN. MECHANIC HAS PERFORMED PRESSURE TEST TO NO AVAIL. NO COOLANT ON GROUND AT ANY POINT. NO VISIBLE SIGNS OF LEAK. THIS BEGAN RIGHT AFTER 2ND CRACKED FLYWHEEL WAS REPLACED. AT THE SAME TIME A LIFTER KNOCK BEGAN AS WELL. 1ST FLYWHEEL WAS REPLACED AT 103K…

Apr 15, 2010 · Power train
REPEATED CRACKED FLYWHEEL. ORIGINAL CRACKED JUST OVER 100K MILES. REPLACEMENT NOW CRACKED 40K MILES LATER.

Express 2500 model years compared

Year	Recalls	Complaints	Crashes	Fires
2001	0	2	0	0
2002	0	1	0	0
2003	0	12	0	0
2004	1	8	1	0
2005	0	9	2	1
2006	0	13	2	0
2007	0	7	1	0

All Chevrolet Express 2500 years →

Questions

Does the 2004 Chevrolet Express 2500 have any recalls?: Yes. NHTSA lists 1 recall for the 2004 Chevrolet Express 2500, the most recent reported on December 13, 2005 (Exterior lighting). Check a specific car by its VIN at nhtsa.gov/recalls.
What are the most common problems with the 2004 Chevrolet Express 2500?: Owners have filed 8 complaints with NHTSA. The most frequently reported area is power train (3 complaints), followed by engine and engine cooling (2).
How many 2004 Chevrolet Express 2500 complaints mention a crash or fire?: 1 of 8 complaints report a crash and 0 a fire; 0 injuries were reported in total. Complaints are unverified reports from owners.

Source: NHTSA recall and complaint data, updated October 27, 2026. Latest complaint received October 5, 2016.