2004 Chevrolet Express 3500 Body and structure Problems
- Complaints
- 2about this part
- Share
- 13%of 16 total for the year
- Median mileage
- 25,000miles
- Trend
- Not enough dataFewer than 15 complaints, too few for a reliable trend.
NHTSA recorded 2 complaints about the body and structure of the 2004 Chevrolet Express 3500, 13% of the 16 complaints for this model year. Where a mileage was given, the median is 25,000 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 contact owns a 2004 Chevrolet EXPRESS 3500. The contact stated that the passenger and driver side door hinges were fractured. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The approximate failure mileage was 25,000.”
NHTSA complaint #10594475, filed 2014-05, 25,000 miles“Faulty hinge pins on side doors of 2004 chevy 3500 express van cause severe binding of hinges. This could cause exit difficulty for child or elderly trying to exit in case of accident or emergency. It is a problem with multiple years and pins have been redesigned. Chevy will only repair at customers expense. This is not from damage or neglect. I have tried to lubricate with no success.”
NHTSA complaint #10205561, filed 2007-10Related service bulletins
- 10190934Jan 1, 2014Underbody Component Corrosion The following information may be helpful when addressing underbody component corrosion with customers. Some customers may comment that one or more…
- 10190933Jan 1, 2014Underbody Component Corrosion The following information may be helpful when addressing underbody component corrosion with customers. Some customers may comment that one or more…
- 10037570Apr 1, 2012Gm: on some truck models there is some frame corrosion. *rm updated on 5/2/2012.
Body and structure: other model years
Other parts of the 2004 Chevrolet Express 3500
5 complaintsFuel system
4 complaintsSteering
4 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 28, 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