CHEVROLET EXPRESS 2500 · model year

2004 CHEVROLET EXPRESS 2500

10 NHTSA complaints, 1 crash report, and 2 active recalls for this specific cohort.

NHTSA overall rating

Not crash-tested

New Car Assessment Program

The 2004CHEVROLETEXPRESS 2500 carries 10 consumer safety complaints in NHTSA's Office of Defects Investigation database for this specific model-year cohort. Within that volume, owners reported 1 crash, 0 fires, 0 injuries, and 0 fatalities. No NCAP 5-star crash-test rating is available for this model year in the federal database.

Component-level analysis is where model-year complaints become actionable: the top complaint category for the 2004 EXPRESS 2500 is engine and engine cooling with 2 filings, followed by power train (2) and service brakes, hydraulic:antilock/traction control/electronic limited slip (1). Concentration in one or two component groups is the classic signature of a systemic defect; a flat distribution usually reflects normal aging, warranty complaints, or isolated build-plant variability. This model year has 2 active recall campaigns, which means the manufacturer is obligated to remedy the covered defect at no charge for the life of the vehicle — the full NHTSA campaign numbers are listed below.

NHTSA currently has 57 investigation files overlapping the 2004 EXPRESS 2500, and 2 remain open. Owners comparing this cohort against neighboring years should pair the counters above with the complaint-by-year trend on the parent model page — a spike in a single year often tracks to a platform refresh, a new transmission supplier, or an updated ECU calibration. Use the related-complaint feed below to read raw owner narratives before deciding whether any pattern here affects your specific use case.

10
Complaints
1
Crashes
0
Fires
0
Injuries
0
Deaths

Total Complaints

10 filings

Crashes Reported

1 reports

Source

NHTSA ODI

Federal complaints database

Complaints vs. fleet median (215)

At or below the fleet median complaint volume.

Complaints by Component

ComponentCount
ENGINE AND ENGINE COOLING2
POWER TRAIN2
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP1
EQUIPMENT1
SERVICE BRAKES, HYDRAULIC1
ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL1
POWER TRAIN:AUTOMATIC TRANSMISSION1
SERVICE BRAKES1

Recalls (2)

06E04300019/05/2006

FUEL SYSTEM, GASOLINE

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 CE

05V55900013/12/2005

EXTERIOR LIGHTING

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

Recent Complaints

20161005SERVICE BRAKES

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 PEDAL TO ENSURE THAT THE VEHICLE CAME TO A COMPLETE STOP. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBERS: 05V043000 (SERVICE BRAKES, HYDRAULIC) AND 04V045000 (SERVICE BRAKES, HYDRAULIC). THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 115,000.

Mileage: 115,000

20130802POWER TRAIN

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. THE APPROXIMATE FAILURE MILEAGE WAS 119,000.

Mileage: 119,000

20120207ENGINE AND ENGINE COOLING

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, FIXED/REPLACED THE BELT. SINCE THAT TIME, I BEGAN TO HEAR A LOW KNOCKING, MORE SO WHEN I TURNED ON THE AIR CONDITIONING. WHEN IT BECAME LOUDER ON ALL GEARS AND WHILE PARKED, I TOOK IT TO HOLLER DRIVERS MART, IN WINTER PARK, FL. ON 01/19/2012, I WAS TOLD THAT THE FLYWHEEL HAD SHEARED AROUND THE AREA WHERE IT WAS BOLTED ONTO THE TRANSMISSION AND CONNECTED TO THE ENGINE. IT ALSO HAD FRACTURES IN AND AROUND THE SAME AREA OF THE SHEARING. TECH INFORMED ME THAT I HAD CAUGHT THE PROBLEM BEFORE A SERIOUS INCIDENT MAY HAVE OCCURRED. I HAVE THE FLY WHEEL AND WILL SEND PHOTOS. CONSUMER SENT IN PHOTOS. 02/07/12 UPDATED 02/07/12 *BF STATUS UPDATE 02/23/12

Mileage: 15,500

20100614ENGINE AND ENGINE COOLING

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 (3K OUTSIDE OF EXTENDED WARRANTY). 2ND FLYWHEEL REPLACED AT 143K. VAN IS KEPT IN MINT CONDITION, OIL CHANGED EVERY 3K W/O FAIL. VEHICLE SEEMS TO BE IN OTHERWISE TERRIFIC CONDITION. 1ST AND ONLY OWNER. DATE REFERRED TO IS DATE OF 2ND FLYWHEEL CRACK. *TR

Mileage: 103,000

20100614POWER TRAIN

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 (3K OUTSIDE OF EXTENDED WARRANTY). 2ND FLYWHEEL REPLACED AT 143K. VAN IS KEPT IN MINT CONDITION, OIL CHANGED EVERY 3K W/O FAIL. VEHICLE SEEMS TO BE IN OTHERWISE TERRIFIC CONDITION. 1ST AND ONLY OWNER. DATE REFERRED TO IS DATE OF 2ND FLYWHEEL CRACK. *TR

Mileage: 103,000

20100415POWER TRAIN:AUTOMATIC TRANSMISSION

REPEATED CRACKED FLYWHEEL. ORIGINAL CRACKED JUST OVER 100K MILES. REPLACEMENT NOW CRACKED 40K MILES LATER. *TR

20100115SERVICE BRAKES, HYDRAULIC

I OWN A 2004 SILVERADO 2500 HD WITH 26,500 MILES ON IT. I HAD MY TRUCK SERVICED FOR SPEEDOMETER THAT WAS NOT WORKING AND WAS TOLD BY KARL CHEVY HERE IN ANKENY, IA THAT ALL OF MY ROTORS AND BRAKE PADS NEEDED TO BE REPLACED BECAUSE OF RUST. GM OUGHT TO FIX MY BRAKES FOR FREE, THEY NEED TO RECALL. I AM 61 AND HAVE OWNED A FEW AUTOMOBILES AND HAVE NEVER HAD TO REPLACE ROTORS WITH SUCH LOW MILEAGE. THE MAJORITY OF MILES ARE HIGHWAY. I HAVE BEEN IN A RIDESHARE POOL USING A METRO VAN PROVIDED TO OUR POOL FOR THE LAST FOUR YEARS AS THE MAIN DRIVER. *TR

Mileage: 26,500

20100115ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL

I OWN A 2004 SILVERADO 2500 HD WITH 26,500 MILES ON IT. I HAD MY TRUCK SERVICED FOR SPEEDOMETER THAT WAS NOT WORKING AND WAS TOLD BY KARL CHEVY HERE IN ANKENY, IA THAT ALL OF MY ROTORS AND BRAKE PADS NEEDED TO BE REPLACED BECAUSE OF RUST. GM OUGHT TO FIX MY BRAKES FOR FREE, THEY NEED TO RECALL. I AM 61 AND HAVE OWNED A FEW AUTOMOBILES AND HAVE NEVER HAD TO REPLACE ROTORS WITH SUCH LOW MILEAGE. THE MAJORITY OF MILES ARE HIGHWAY. I HAVE BEEN IN A RIDESHARE POOL USING A METRO VAN PROVIDED TO OUR POOL FOR THE LAST FOUR YEARS AS THE MAIN DRIVER. *TR

Mileage: 26,500

20060607EQUIPMENT

DT*: THE CONTACT STATED THE ELECTRICAL MODULE THAT CONTROLS THE AUDIO WARNING SYSTEM IS LOCATED IN THE ORIGINAL RADIO. THE CONTACT SWITCHED THE RADIO AND LOST ALL OF THE AUDIO WARNING SYSTEMS. THE DEALER AND MANUFACTURER WAS ALERTED AND DETERMINED THE MODULE WAS IN THE ORIGINAL RADIO AND IT SHOULD BE PUT BACK IN THE VEHICLE.

Mileage: 21,000

20060111CrashSERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP

DURING A SUDDEN STOP CHEVY 2500 EXPRESS ABS BRAKES PULLED TO THE RIGHT OR LEFT. *TS THE CONSUMER STATED THE PROBLEM USUALLY OCCURRED DURING A PANIC STOP. THE CONSUMER STATED HE HAD THREE SEPARATE ACCIDENTS BECAUSE OF THE DEFECTIVE BRAKES. *JB

Compare 2004CHEVROLETEXPRESS 2500 to Similar Vehicles

NHTSA Investigations 2 Open

View all investigations

Frequently Asked Questions

How many complaints does the 2004 CHEVROLET EXPRESS 2500 have?
The 2004 CHEVROLET EXPRESS 2500 has 10 NHTSA complaints, 1 crashes, 0 fires, 0 injuries, and 0 deaths reported.
Are there any recalls for the 2004 CHEVROLET EXPRESS 2500?
Yes, the 2004 CHEVROLET EXPRESS 2500 has 2 recall(s). The most common affected component is FUEL SYSTEM, GASOLINE. Recalls are issued by NHTSA and manufacturers must provide a free remedy.
What are the most common problems with the 2004 CHEVROLET EXPRESS 2500?
The most-complained component for the 2004 CHEVROLET EXPRESS 2500 is ENGINE AND ENGINE COOLING with 2 complaints. Other frequently reported areas include POWER TRAIN and SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP.
Is the 2004 CHEVROLET EXPRESS 2500 safe to buy?
Review the complaint history, crash and fire reports, safety ratings, and recall status on this page to make an informed decision. No NHTSA crash test rating is available for this model year. Compare with other model years using the links above.
Where does this data come from?
All complaint, recall, and safety rating data is sourced from the National Highway Traffic Safety Administration (NHTSA). Complaints are filed by vehicle owners through NHTSA's Office of Defects Investigation.

Vehicle Safety Guides

Data as of 2025. Sources: NHTSA Office of Defects Investigation (ODI) complaints database, NHTSA recall campaign API, NHTSA NCAP crash-test ratings, and NHTSA FARS for fatality cross-reference.