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 recalls
Fuel system, gasoline: storage, tank assembly, filler pipe and cap
NHTSA campaign 12V388000 · reported August 8, 2012 · GENERAL MOTORS LLC · 9,389 vehicles potentially affected
- The problem
- 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.
- The 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.
- The fix
- 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.
Seat belts
NHTSA campaign 05V558000 · reported December 19, 2005 · GENERAL MOTORS CORP. · 425,593 vehicles potentially affected
- The problem
- On certain full-size passenger, cargo, or cutaway vans, the front and rear seat belt buckles will not latch or will not unlatch.
- The risk
- In the event of a crash, a seat occupant may not be properly restrained increasing the risk of personal injury.
- The fix
- 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.
Service brakes, hydraulic
NHTSA campaign 05V043000 · reported February 8, 2005 · GENERAL MOTORS CORP. · 77,411 vehicles potentially affected
- The problem
- 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.
- The risk
- 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.
- The fix
- 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.
Power train: automatic transmission, lever and linkage, column shift
NHTSA campaign 04V320000 · reported July 6, 2004 · GENERAL MOTORS CORP. · 1,792 vehicles potentially affected
- The problem
- 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.
- The risk
- If this were to occur, the vehicle could move in a direction not anticipated by the driver, which could result in a vehicle crash.
- The fix
- 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.
Seat belts: front, buckle assembly
NHTSA campaign 04V189000 · reported April 19, 2004 · GENERAL MOTORS CORP. · 331 vehicles potentially affected
- The problem
- 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.
- The risk
- The safety belt may not restrain the occupant as intended during a crash, which could result in injury to the occupant.
- The fix
- 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.
Service brakes, hydraulic
NHTSA campaign 04V045000 · reported February 4, 2004 · GENERAL MOTORS CORP. · 68,875 vehicles potentially affected
- The problem
- 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.
- The risk
- 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.
- The fix
- 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.
What owners report
Recent complaints filed with NHTSA, shortened. These are unverified accounts from owners, not findings.
Mar 1, 2022 · 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.
Dec 30, 2021 · 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 assembly could come off or the frame could break in half, by just going over say, a railroad crossing…
Nov 9, 2016 · Fuel/propulsion system · 148,000 miles
TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS. WHILE THE VEHICLE WAS STATIONARY, FUEL SPILLED ONTO THE GROUND. IT WAS DIAGNOSED THAT THE FILLER NECK WAS CORRODED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE. THE FAILURE MILEAGE WAS 148,000. UPDATED 04/11/2017
Oct 17, 2016 · Visibility/wiper · 33,000 miles
TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS. WHILE THE VEHICLE WAS PARKED THE REAR DRIVER'S SIDE WINDOW FELL OUT OF PLACE. THE CONTACT STATED THAT ALL THE WINDOWS ON THE VEHICLE WERE LOOSE. THERE NO WARNING LIGHTS ILLUMINATED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE ISSUE. THE…
Sep 8, 2016 · Structure · 150,000 miles · fire reported
THE VAN WAS PARKED IN MY DRIVEWAY STATIONARY. IT CAUGHT FIRE AND PROCEEDED TO BURN COMPLETELY FOR UNKNOWN REASONS. THE WEBSITE STATES THIS VIN NUMBER IS NOT INCLUDED IN ANY RECALLS BUT THE VEHICLE TYPE HAS A RECALL LISTED THAT STATES IT COULD BE A FIRE HAZARD.
Source: NHTSA recall and complaint data, updated October 27, 2026. Latest complaint received March 1, 2022.