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Chevrolet ExpressModel year report

2004 Chevrolet Express Problems

Complaints
21filed with NHTSA
Median mileage
87,000miles, 18 complaints with mileage
Recalls
6campaigns on record
Trend
FallingComplaints filed in the last 3 full calendar years are at least 25% lower than in the 3 years before.
NHTSA crash rating
—overall rating starts with 2011 models
EPA fuel economy
15 mpgcombined, 4.3L 6-cyl RWD · 13 city / 18 hwy

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

NHTSA recorded 21 consumer complaints for the 2004 Chevrolet Express. The part named most often is brakes, with 6 complaints (29% of the total), followed by fuel system (4) and seat belts (3). 18 of the complaints include a mileage, and 39% of those were filed for vehicles with under 50,000 miles; the median is 87,000 miles. Of all complaints, 1 involved a crash, 2 a fire, according to the filers. NHTSA lists 6 recall campaigns and 510 technical service bulletins for this model year. Brakes complaints overlap with 2 recall campaigns and 18 technical service bulletins filed under the same part. Fuel system complaints overlap with 1 recall campaign covering the filler pipe and cap and 33 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.

Also reported: Transmission and drivetrain (1), Visibility (wipers, defrost, mirrors) (1).

Example complaints

Brakes: “On june 20th, 2008 we brought our van in for a routine brake inspection and wheel alignment at 36,117 miles. We also noticed a noise in the rear when making a turn. The mechanic indicated that the brake backing plates on both sides were rusted, and the left rear backing plate was rotted to the point that it had holes in it. The mechanic indicated that the replacement parts were inexpensive, but the labor was intensive and would probably cost in the neighborhood of $600. …”

NHTSA complaint #10245517, filed 2008-10, 36,117 miles

Fuel system: “Our 2004 chevy Express van stalled serveral(12) times within a 14 mile distance on the interstate in denver, co. The wife was able to get it home, and we contacted the local chevy dealer (stevenson chevy, golden co.) the service advisor advised us that chevy is having a problem with fuel pumps overheating and is working the problem. No recall has been issued for the fuel pump problem from chevy. Yes, the fuel pump was replace at sevenson chevy in golden, co on 21 july. This is our second occurance of a fuel pump failure in a new chevy vehicle. …”

NHTSA complaint #10129686, filed 2005-07, 19,250 miles

Seat belts: “The contact stated the seat belt buckle did not release the seat belt properly. Intermittently, the seat belt became stuck in the buckle. The notice for NHTSA recall #05v558000, pertaining to the seat belts, was received. The vehicle was taken to a service dealer, where the dealer denied a free remedy due to the problem only being intermittent. The manufacturer was notified, who stated the buckle assembly would only be replaced if the problem could be replicated at the dealership.”

NHTSA complaint #10171403, filed 2006-10, 50,000 miles

Steering: “Vehicle has continued to evidence problems similar to what's described by NHTSA campaign id no. 04v452000. Power steering pump and belts have been replaced and GM dealer performed hydro boost inspection test and it passed; said no further action required. Bus has again lost power steering and brakes to cause a dangerous condition. Dealer says it is not a vehicle that recall applies to.”

NHTSA complaint #10455608, filed 2012-04, 118,000 miles

Mileage when problems were reported

39% of the 18 complaints with a mileage were filed for vehicles with under 50,000 miles; the middle half falls between 36,117 and 140,000 miles.

0%0–1011%10–2528%25–5011%50–750%75–10039%100–15011%150+
Share of complaints by mileage when the problem was reported, in thousands of miles (18 complaints with mileage). Red bars: under 50,000 miles. Bucket widths differ. Median: 87,000 miles.

Complaints by year filed

Trend: falling. Complaints filed in the last 3 full calendar years are at least 25% lower than in the 3 years before.

4200620112013201642022
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 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 1500/2500 2WD4.3L 6-cyl4-speed automatic131815$4,450
Express 1500/2500 2WD5.3L 8-cyl4-speed automatic141815$4,450
Express Cargo (Bi-fuel) RWD6.0L 8-cyl · bifuel (cng)4-speed automatic111512$5,600
Express Passenger (Bi-fuel) RWD6.0L 8-cyl · bifuel (cng)4-speed automatic111512$5,600
Express Cargo (dedicated CNG) RWD6.0L 8-cyl · natural gas4-speed automatic111512$3,850
Express Passenger (dedicated CNG) RWD6.0L 8-cyl · natural gas4-speed automatic111512$3,850

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

Recall details for the 2004 Chevrolet Express → · Check a 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. 510 on record; the latest 10 are shown.

See all 510 bulletins →

Other model years of the Chevrolet Express

YearComplaintsMedian miRecallsCrash ★MPGScore (50 = typical)Trend
20211311,5002———Not enough data
20201762,3761———Rising
201985,3924———Not enough data
2018119,9426———Not enough data
20172118,0006—13—Rising
20161521,2536—13—Stable
2015824,0003—13—Not enough data
20141430,9507—13—Not enough data
20132219,6628—14—Falling
20121338,5006—13—Not enough data
20111294,0365—12—Not enough data
20101547,8505———Falling
20091051,0007———Not enough data
20081442,47510—14—Not enough data
20071865,0004—15—Falling
20061262,52916—15—Not enough data
20052385,9348—15—Falling
20042187,0006—15—Falling
20035946,82410—15Not compared (before 2008)Stable
20025633,0000—14Not compared (before 2008)Falling
20014545,0002—14Not compared (before 2008)Falling
20008455,8751—14Not compared (before 2008)Falling
19996868,6121—14Not compared (before 2008)Stable
19982361,1251—14—Stable
19972982,0001—14Not compared (before 2008)Stable
19961558,5002—14—Stable

All Chevrolet Express model years · Best and worst years by complaints

Frequently asked questions

How many NHTSA complaints does the 2004 Chevrolet Express have?

NHTSA recorded 21 consumer complaints for the 2004 Chevrolet Express as of Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.

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

Brakes is named most often, in 6 complaints (29% of the total), followed by fuel system with 4.

Has the 2004 Chevrolet Express been recalled?

NHTSA lists 6 recall campaigns for this model year. To check a specific vehicle, enter its VIN at nhtsa.gov/recalls.

What gas mileage does the 2004 Chevrolet Express get?

The EPA rates the 2004 Chevrolet Express (Express 1500/2500 2WD, 4.3L 6-cyl) at 15 mpg combined, 13 city and 18 highway, with an estimated annual fuel cost of $4,450 at 15,000 miles a year. Other engine and drive versions are rated differently.

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

Among the 18 complaints that include a mileage, the median is 87,000 miles and the middle half falls between 36,117 and 140,000 miles; 39% were filed for vehicles with under 50,000 miles.

About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 27, 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.