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BrakesPart report

2004 Chevrolet Express 3500 Brakes Problems

Complaints
5about this part
Share
31%of 16 total for the year
Median mileage
50,000miles
Trend
Not enough dataFewer than 15 complaints, too few for a reliable trend.

NHTSA recorded 5 complaints about the brakes of the 2004 Chevrolet Express 3500, 31% of the 16 complaints for this model year. Where a mileage was given, the median is 50,000 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 brakes on my 2004 chevy EXPRESS 3500 activate without warning, stopping the vehicle in traffic. A warning light indicated a failure of the stability control system. Fault code c0196 was recorded. My dealer replaced the electronic brake control module, but the problem continues to occur. I was almost rear-ended when the vehicle stopped without warning in traffic.”

NHTSA complaint #10275040, filed 2009-06, 50,000 miles

“2004 Chevrolet express collins school bus while driving at 15 MPH on an inclined rural country road attempting to brake noticed pedal extended to the floor and was stopped by further down shifting and applying emergency brake. Informed by repair shop the right front hydraulic line rubbed through the metal brake line causing the failure. Failure mileage 43,997.”

NHTSA complaint #10854900, filed 2016-04, 43,997 miles

“The contact owns a 2004 Chevrolet EXPRESS 3500. The contact stated while driving down a mountain road approximately 45 MPH the brake pedal was depressed and the vehicle began to vibrate excessively and the brake discs overheated. The failure was not diagnosed nor was the vehicle repaired. The manufacturer was notified of the defect. The approximate failure mileage was 128,000. Updated 08/11/14 updated 08/18/2014”

NHTSA complaint #10593709, filed 2014-05, 128,000 miles

“The contact stated while driving on the highway at various speeds for an extended period of time with brakes depressed, the steering wheel violently shook. The vehicle was inspected by a dealer who turned the brake rotors. Afterwards, the problem persisted. The vehicle was taken back to the dealer who as unable to duplicate the problem. The manufacturer was contacted.”

NHTSA complaint #10164314, filed 2006-08, 9,800 miles

“The contact owns a 2004 Chevrolet cargo express van 3500. While driving 45 MPH he had attempted to brake and noticed that the brake pedal extended to the floor and the vehicle could only be stopped by manually down shifting the gears. The dealer informed the contact that the coolant line rubbed through to the brake line. There was a burning smell prior to the failure in the front axle area of the vehicle. The current and failure mileages were 66445.”

NHTSA complaint #10281151, filed 2009-08, 66,445 miles

Related service bulletins

Brakes: other model years

YearComplaintsShare of year
2008218%
2006213%
2005318%
2004531%
200318%
2001218%

Other parts of the 2004 Chevrolet Express 3500

Fuel system
4 complaints
Steering
4 complaints
Body and structure
2 complaints
Electronic stability control
1 complaints
Tires
1 complaints

← All problems reported for the 2004 Chevrolet Express 3500

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