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Chevrolet Express 1500Model year report

2004 Chevrolet Express 1500 Problems

Complaints
12filed with NHTSA
Median mileage
102,524miles, 10 complaints with mileage
Recalls
0campaigns on record
Trend
Not enough dataFewer than 15 complaints, too few for a reliable trend.
NHTSA crash rating
—overall rating starts with 2011 models
EPA fuel economy
14 mpgcombined, 5.3L 8-cyl 4WD/AWD · 13 city / 17 hwy

Sources: NHTSA records for the 2004 Chevrolet Express 1500 (complaints, recalls, investigations), EPA fuel economy. Report an error

NHTSA recorded 12 consumer complaints for the 2004 Chevrolet Express 1500. The part named most often is brakes, with 3 complaints (25% of the total), followed by fuel system (3) and air bags (2). 10 of the complaints include a mileage, and 40% of those were filed for vehicles with under 50,000 miles; the median is 102,524 miles. Of all complaints, 1 involved a crash, 1 a fire, 1 an injury, according to the filers. NHTSA lists 0 recall campaigns and 89 technical service bulletins for this model year. Brakes complaints overlap with 1 technical service bulletin filed under the same part. Fuel system complaints overlap with 2 technical service bulletins filed under the same part.

This model year has fewer than 25 complaints on record, so the numbers below can change a lot with a few new reports.

Which parts are reported most

Complaints can name more than one part, so the counts add up to more than the total. Select a part to see its complaints, recalls and bulletins.

Example complaints

Brakes: “Abs engages at slow speed, at tail end of braking, even on dry surfaces. This has been going on for at least eight months. Started sometime in early summer/late spring 2008.”

NHTSA complaint #10263589, filed 2009-03, 35,000 miles

Fuel system: “The fuel filler tube leaks fuel, is corroded. And also the rear fuel tank strap, at the top of the chassis is also corroded, and the fuel tank is hanging down, causing a risk and fire hazzard as it is very close to the driveshaft.”

NHTSA complaint #10823319, filed 2016-01, 160,000 miles

Visibility (wipers, defrost, mirrors): “Windshield is full of what looks like scratches, but it must be in lamination (?), because you can't feel them on either the interior or exterior of the glass. Gradually getting worse, causing annoying vision through the windshield. No real incident date, just gradually getting worse, spreading.”

NHTSA complaint #10160002, filed 2006-06

Mileage when problems were reported

40% of the 10 complaints with a mileage were filed for vehicles with under 50,000 miles; the middle half falls between 33,000 and 160,000 miles.

0%0–1020%10–2520%25–500%50–7510%75–10020%100–15030%150+
Share of complaints by mileage when the problem was reported, in thousands of miles (10 complaints with mileage). Red bars: under 50,000 miles. Bucket widths differ. Median: 102,524 miles.

Complaints by year filed

Fewer than 15 complaints, too few for a reliable trend.

2200720092201120152019
Complaints by year the complaint was filed with NHTSA. Red bars: the last 3 full calendar years used for the trend. The current year (2026) is partial.

Fuel economy and running cost

EPA ratings for each 2004 Chevrolet Express 1500 version. Annual fuel cost is the EPA's estimate at its current fuel prices for 15,000 miles a year (55% city driving).

VersionEngineTransmissionCityHwyComb.Fuel / yr
Express 1500 AWD5.3L 8-cyl4-speed automatic131714$4,800

Source: U.S. EPA and Department of Energy, fueleconomy.gov. Ratings are for comparing vehicles; real-world mileage varies with driving and conditions.

Recalls and investigations

NHTSA lists no recall campaigns for the 2004 Chevrolet Express 1500 in the data used here. A recall can apply to some vehicles of a model year and not others, so check a specific vehicle by VIN at nhtsa.gov/recalls.

Technical service bulletins

TSBs are manufacturer notes to dealers about known repair procedures. They are not recalls and do not by themselves mean a vehicle has a fault. 89 on record; the latest 10 are shown.

See all 89 bulletins →

Other model years of the Chevrolet Express 1500

YearComplaintsMedian miRecallsCrash ★MPGScore (50 = typical)Trend
20141057,5000—15—Not enough data
2009570,7100—14—Not enough data
2008980,0000—14—Not enough data
2007517,2341—14—Not enough data
2006541,0000—14—Not enough data
20051053,8000—14—Not enough data
200412102,5240—14—Not enough data
20031899,7320—13—Stable
20021037,0000———Not enough data
2001568,0000———Not enough data
20006100,0000———Not enough data

All Chevrolet Express 1500 model years

Frequently asked questions

How many NHTSA complaints does the 2004 Chevrolet Express 1500 have?

NHTSA recorded 12 consumer complaints for the 2004 Chevrolet Express 1500 as of Oct 29, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.

What part of the 2004 Chevrolet Express 1500 is reported most often?

Brakes is named most often, in 3 complaints (25% of the total), followed by fuel system with 3.

Has the 2004 Chevrolet Express 1500 been recalled?

NHTSA lists no recall campaigns for this model year in the data used here. To check a specific vehicle, enter its VIN at nhtsa.gov/recalls.

What gas mileage does the 2004 Chevrolet Express 1500 get?

The EPA rates the 2004 Chevrolet Express 1500 (Express 1500 AWD, 5.3L 8-cyl) at 14 mpg combined, 13 city and 17 highway, with an estimated annual fuel cost of $4,800 at 15,000 miles a year. Other engine and drive versions are rated differently.

At what mileage are problems with the 2004 Chevrolet Express 1500 reported?

Among the 10 complaints that include a mileage, the median is 102,524 miles and the middle half falls between 33,000 and 160,000 miles; 40% were filed for vehicles with under 50,000 miles.

About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 29, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate. Fuel economy is from the EPA and DOE (fueleconomy.gov).

Complaint counts come from NHTSA’s public complaint database; we count each complaint once. The source records for this vehicle are on nhtsa.gov. Scores and trends are our own summaries of that data, described in the methodology. This page is not legal, safety or repair advice: for a specific vehicle, check its VIN at nhtsa.gov/recalls and ask a qualified mechanic. See an error? Tell us.