2004 Chevrolet Express Recalls
NHTSA lists 6 recall campaigns for the 2004 Chevrolet Express. A recall applies only to vehicles built within the affected range, so check your own VIN at nhtsa.gov/recalls. Repairs for recalls are free at a franchised dealer.
- Fuel system, gasoline › Storage › Tank assembly › Filler pipe and capCovers: Chevrolet Express 2003–2004, GMC Savana 2003–2004
Reported issue: 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, West Virginia, Wisconsin, and the…
Possible consequence: Significant corrosion may allow fuel to leak during refueling, and in the presence of an ignition source; there is an increased risk of fire.
Remedy: GM will notify owners, and dealers will install a new fuel filler neck, free of charge. The safety recall began on October 1, 2012. Owners may contact the Chevrolet owner center at 1-866-694-6546 and GMC at 1-866-996-9463.
- Seat beltsCovers: Chevrolet Express 2003–2006, GMC Savana 2003–2006
Reported issue: On certain full-size passenger, cargo, or cutaway vans, the front and rear seat belt buckles will not latch or will not unlatch.
Possible consequence: In the event of a crash, a seat occupant may not be properly restrained increasing the risk of personal injury.
Remedy: Dealers will inspect the buckles and, if found to be inoperative, the entire buckle assembly would be replaced. For buckles found to be operative, dealer will replace only the upper buckle cover. The recall will be conducted in phases. The first phase mailing began during march 2006. Owners may contact chevrolet at…
- Service brakes, hydraulicCovers: Chevrolet Express 2004–2005, Silverado 2004–2005, GMC Savana 2004–2005 +7 more
Reported issue: Certain trucks, sport utility vehicles, and vans equipped with bosch hydro-boost brake assemblies, the hydraulic brake booster pressure accumulator may crack and separate from the hydro-boost assembly during normal operating conditions.
Possible consequence: If a separation occurred and the hood of the vehicle were open, fragments from the accumulator could cause injury to people in the immediate area. The presence of this crack or fractured surface could allow the hydraulic fluid to leak from the accumulator circuit of the booster assembly. The loss of fluid would cause…
Remedy: Dealers will test the hydro-boost assembly for functional operation of the two-function valve. If the hydro-boost assembly fails the test, dealers will replace the assembly free of charge. The recall began on march 23, 2005. Owners may contact chevrolet at 1-800-630-2438, gmc trucks at 1-866-996-9463 and hummer at…
- Power train › Automatic transmission › Lever and linkage › Column shiftCovers: Chevrolet Express 2004, GMC Savana 2004
Reported issue: Certain vans were built with a transmission shift cable assembly that may separate. If the cable assembly separates, the transmission shift lever position and the transmission indicator may no longer correlate.
Possible consequence: If this were to occur, the vehicle could move in a direction not anticipated by the driver, which could result in a vehicle crash.
Remedy: Dealers will inspect the transmission shift cable assembly, and if necessary, replace it. The recall began on august 19, 2004. Owners should contact chevrolet at 1-800-630-2438 or gmc at 1-866-996-9463.
- Seat belts › Front › Buckle assemblyCovers: Chevrolet Express 2004, GMC Savana 2004
Reported issue: Certain vans fail to conform to the requirements of federal motor vehicle safety standard no. 209, "seat belt assemblies." these vehicles may have been produced with seat belt buckle assemblies containing a latch with a brittle condition that may not withstand the force requirements of the standard.
Possible consequence: The safety belt may not restrain the occupant as intended during a crash, which could result in injury to the occupant.
Remedy: Dealers will replace the safety belt buckle. The recall beagn may 7, 2004. Owners should contact chevrolet at 1-800-630-2438 or gmc at 1-866-996-9463.
- Service brakes, hydraulicCovers: Chevrolet Express 2003–2004, Silverado 2003–2004, GMC Yukon 2003–2004 +10 more
Reported issue: Certain sport utility vehicles, pickup trucks, and passenger vans fail to comply with the requirements of federal motor vehicle safety standard no. 135, ?passenger car brake systems.? Some of these vehicles were produced with an out-of-specification brake hydro-boost housing relief valve bore.
Possible consequence: Consequently, the valve o-ring seal may fracture. Steering efforts may be slightly increased while braking or parking. Under certain driving conditions, a fractured seal may require a slight increase in the applied brake pedal effort to achieve the same vehicle deceleration rate as prior to the seat fracture.
Remedy: Dealers are to replace the hydro-boost relief valve. The recall began on june 18, 2004. Owners should contact cadillac at 1-866-982-2339; chevrolet at 1-800-630-2438; gmc at 1-866-996-9463; or hummer at 1-866-486-6376.
← All problems reported for the 2004 Chevrolet Express
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 29, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.