2004 Chevrolet Express 3500 Fuel system Problems
- Complaints
- 4about this part
- Share
- 25%of 16 total for the year
- Median mileage
- 117,000miles
- Trend
- Not enough dataFewer than 15 complaints, too few for a reliable trend.
NHTSA recorded 4 complaints about the fuel system of the 2004 Chevrolet Express 3500, 25% of the 16 complaints for this model year. Where a mileage was given, the median is 117,000 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.
“Gasoline and gasoline vapor was escaping from the fuel filler pipe leading to the fuel tank on a 2004 chevy express van 3500 series. The filer pipe was rusted through. There was a seam on the pipe where the rust through occurred. Gasoline was dripping from this hole during gasoline fill up and vapors were entering the passenger compartment. We had it replaced by a certified mechanic because it was a potentially explosive situation, according to the mechanic. This was reported to GM. There was no recall on this part, so GM refused to pay for the cost of the replacement part and labor. …”
NHTSA complaint #10463960, filed 2012-07, 170,000 miles“The contact owns a 2004 Chevrolet EXPRESS 3500. The contact stated that the fuel tank pipe was severely rusted and was leaking. The vehicle was taken to an independent mechanic for diagnosis. The vehicle was not repaired. The manufacturer was not made aware of the defect. The approximate failure mileage was 39,000. The VIN was unavailable.”
NHTSA complaint #10510492, filed 2013-05, 39,000 miles“The contact owns a 2004 Chevrolet EXPRESS 3500. The contact stated the fuel filler neck tube was corroded, causing fuel to leak when refueling the vehicle. The contact referenced NHTSA campaign number: 12v388000 (fuel system, gasoline) but was advised by the manufacturer that the VIN was not included in the recall. The vehicle was not repaired. The approximate failure mileage was 130,000.”
NHTSA complaint #10553177, filed 2013-11, 130,000 milesRelated service bulletins
- 11004761Jun 28, 2024This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or…
- 10171878Jan 2, 2020This informational bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended…
Fuel system: other model years
Other parts of the 2004 Chevrolet Express 3500
5 complaintsSteering
4 complaintsBody and structure
2 complaintsElectronic stability control
1 complaintsTires
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