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Fuel systemPart report

2004 Chevrolet Express 1500 Fuel system Problems

Complaints
3about this part
Share
25%of 12 total for the year
Median mileage
114,000miles
Trend
Not enough dataFewer than 15 complaints, too few for a reliable trend.

NHTSA recorded 3 complaints about the fuel system of the 2004 Chevrolet Express 1500, 25% of the 12 complaints for this model year. Where a mileage was given, the median is 114,000 miles.

Fewer than 15 complaints name this part, so treat the figures as a rough indication only.

Example complaints

Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.

“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

“My 2004 cutaway chevy sold as a 2005 four winds has the exact problem for this recall. Recall number 12v388000 recall date 08/08/2012 component fuel system, gasoline:storage:tank assembly:filler pipe and cap summary 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…”

NHTSA complaint #11171110, filed 2019-01, 33,000 miles

“The contact owns a 2004 Chevrolet express. The contact stated that after refueling, fuel spew back out of the filler neck. The manufacturer was made aware of the failure who did not offer any assistance since the vehicle was not included in NHTSA campaign id number: 12v388000 (fuel system, gasoline: storage: tank assembly: filler pipe and cap). The failure and current mileage was 114,000. Updated 10/16/12 the consumer stated the fuel filler neck corroded updated 10/19/2012”

NHTSA complaint #10471862, filed 2012-08, 114,000 miles

Related service bulletins

Fuel system: other model years

YearComplaintsShare of year
2006240%
2004325%
2003950%

Other parts of the 2004 Chevrolet Express 1500

Brakes
3 complaints
Air bags
2 complaints
Visibility (wipers, defrost, mirrors)
2 complaints
Electrical system
1 complaints
Engine
1 complaints
Engine cooling
1 complaints
Body and structure
1 complaints
Tires
1 complaints

← All problems reported for the 2004 Chevrolet Express 1500

About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 31, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.

To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology