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FaultScore report

2004 Chevrolet Express 1500 problems

Owners have filed 15 complaints about the 2004 Chevrolet Express 1500 with NHTSA between 2006 and 2019. The largest single group is the brakes. Across this model's run it ranks 1 of 7 worst.

Read the complaints What breaks Worst years for the Chevrolet Express 1500 All 2004 cars
D

FaultScore 72/100

Higher is worse. Measured against the other years of the Chevrolet Express 1500.

How this is worked out

The numbers

15

Complaints

3

Crashes reported

1

Fires reported

3

Injuries reported

114,000 mi

Median mileage at failure

Half of reported failures happened before this

38%

Failed under 36,000 miles

Inside a typical bumper-to-bumper warranty

What kind of bad

The letter says how bad. This says what kind — whether this year drew an unusual number of complaints, unusually dangerous ones, or failures that arrived unusually early.

Complaint volume 58 vs 50 Severity 100 vs 50 Early failure 66 vs 50
The dashed ring is 50 — the national norm. Further out is worse.
Complaint volume — 58
Against the median year of the Chevrolet Express 1500. 50 means typical for this model; 100 means roughly double.
Severity — 100
46.7% of these complaints involved a crash, fire, injury or death, against a national rate of 9.7%.
Early failure — 66
38% of failures with a mileage on record happened under 36,000 miles, against a national rate of 29%.

How 2004 compares with every other Chevrolet Express 1500

Click any bar to open that year's report.

Complaints filed with NHTSA, by model year. Bar colour is the FaultScore grade: A B C D F ungraded

What breaks on a 2004 Chevrolet Express 1500

Every complaint is filed against a part. Follow any row for the complaints about that part alone.

Fuel & Propulsion 3 20.0%

Median failure at 114,000 miles

Brakes 3 20.0%

Median failure at 21,719 miles

Windows, Mirrors & Wipers 2 13.3%

Median failure at 120,000 miles

Airbags 2 13.3%

1 crashes, 0 fires · median 170,524 mi

Engine & Cooling 2 13.3%

1 crashes, 0 fires · median 135,859 mi

Tires 1 6.7%
Body & Structure 1 6.7%

1 crashes, 0 fires · median 250,000 mi

Electrical System 1 6.7%

0 crashes, 1 fires · median 166,000 mi

When it fails

Odometer readings owners gave when they filed. About half of all complaints include one.

10,000 – 24,999 miles 3 23.1%
25,000 – 49,999 miles 2 15.4%
75,000 – 99,999 miles 1 7.7%
100,000 – 149,999 miles 2 15.4%
150,000+ miles 5 38.5%

When owners complained

A spike years after the car went on sale usually means a part wearing out on schedule across the whole fleet — the kind of pattern no single owner can see from inside their own car.

Jun 2006 peak 3 Jan 2019

Complaints that involved harm

Reports where the owner recorded a crash, a fire, an injury or a death.

at 250,000 miles Emporia, VA Crash 1 injured

AIR BAGS

I WAS TRAVELING EAST THRO AN INTERSECTION WHEN A TRUCK ON THE MY RIGHT RAMMED ME IN THE FRONT RIGHT SIDE OF MY CAR.I FELT THE CAR SPIN AND THE TRUCK ENDED UP IN MY RIGHT REAR BUMPER AND WHEN I CAME TO A STOP BOTH AIRBAGS DEPLOYED AND I WAS INJURED AND THE AIRBAGS EXPLODED AND I HAVE EYE DAMAGE TO MY RIGHT EYE AND NECK INJURY AND BACK INJURY. STILL SEEING SPINE DR. AND EYE DR EVERY 6 MONTHS.

NHTSA complaint #10722109 — an unverified report by a vehicle owner.

at 250,000 miles Emporia, VA Crash 1 injured

STRUCTURE:BODY

I WAS TRAVELING EAST THRO AN INTERSECTION WHEN A TRUCK ON THE MY RIGHT RAMMED ME IN THE FRONT RIGHT SIDE OF MY CAR.I FELT THE CAR SPIN AND THE TRUCK ENDED UP IN MY RIGHT REAR BUMPER AND WHEN I CAME TO A STOP BOTH AIRBAGS DEPLOYED AND I WAS INJURED AND THE AIRBAGS EXPLODED AND I HAVE EYE DAMAGE TO MY RIGHT EYE AND NECK INJURY AND BACK INJURY. STILL SEEING SPINE DR. AND EYE DR EVERY 6 MONTHS.

NHTSA complaint #10722109 — an unverified report by a vehicle owner.

at 250,000 miles Emporia, VA Crash 1 injured

ENGINE

I WAS TRAVELING EAST THRO AN INTERSECTION WHEN A TRUCK ON THE MY RIGHT RAMMED ME IN THE FRONT RIGHT SIDE OF MY CAR.I FELT THE CAR SPIN AND THE TRUCK ENDED UP IN MY RIGHT REAR BUMPER AND WHEN I CAME TO A STOP BOTH AIRBAGS DEPLOYED AND I WAS INJURED AND THE AIRBAGS EXPLODED AND I HAVE EYE DAMAGE TO MY RIGHT EYE AND NECK INJURY AND BACK INJURY. STILL SEEING SPINE DR. AND EYE DR EVERY 6 MONTHS.

NHTSA complaint #10722109 — an unverified report by a vehicle owner.

at 166,000 miles Modesto, CA Fire

ELECTRICAL SYSTEM:WIRING:FUSES AND CIRCUIT BREAKERS

TL*THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 1500. THE VEHICLE CAUGHT FIRE INSIDE THE FUSE BOX AFTER BEING PARKED FOR FOUR DAYS. THE FIRE CAUSED DAMAGE TO THE FUSE BOX. AS OF DECEMBER 26, 2007, THE DEALER HAD NOT INSPECTED THE VEHICLE. THE PURCHASE DATE WAS UNKNOWN. THE CURRENT AND FAILURE MILEAGES WERE 166,000.

NHTSA complaint #10212854 — an unverified report by a vehicle owner.

The most recent complaints

In the owners' own words, exactly as filed with NHTSA.

at 33,000 miles Bluff City, TN

FUEL/PROPULSION SYSTEM

MY 2004 CUTAWAY CHEVY SOLD AS A 2005 FOUR WINDS HAS THE EXACT PROBLEM FOR THIS RECALL. RECALL NUMBER 12V388000 RECALL DATE 08/08/2012 COMPONENT FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP SUMMARY 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 DISTRICT OF COLUMBIA. WATER AND ROAD CONTAMINANTS MAY BECOME TRAPPED IN THE PROTECTIVE CONDUIT THAT COVERS THE FUEL FILLER PIPE AND MAY CAUSE THE PIPE TO CORRODE. 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. WHAT OWNERS SHOULD DO 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. THE EXPRESS 1500 I OWN IS CURRENTLY EXHIBITING THIS EXACT ISSUE, AND ALTHOUGH SOLD IN CA IN 2005, BASE VAN WAS MANUFACTURED IN INDIANA MODIFIED BY THOR MOTORHOMES. THIS STATE IS LISTED IN THE RECALL ABOVE. I'M AFRAID TO DRIVE IT, CAN'T AFFORD TO FIX THE ISSUE BEING DISABLED VET ON SMALL SSDI INCOME. IVE THE FEELING IT'S THE SAME MODEL RECALLED, BUT OF COURSE CHEVY WILL NOT REPAIR IT BECAUSE IT IS NOT SPECIFICALLY ON RECALL LIST LIKE THE LEFT SIDE CARGO DOOR MODELS THAT ARE BEING REPAIRED BY THE CHEVROLET GM DEALERS? PLEASE HELP

NHTSA complaint #11171110 — an unverified report by a vehicle owner.

at 160,000 miles Tiverton, RI

FUEL/PROPULSION SYSTEM

THE FUEL FILLER TUBE LEAKS FUEL, IS CORRODED. AND ALSO THE REAR FUEL TANK STRAP, AT THE TOP OF THE CHASSIS IS ALSO CORRODED, AND THE FUEL TANK IS HANGING DOWN, CAUSING A RISK AND FIRE HAZZARD AS IT IS VERY CLOSE TO THE DRIVESHAFT.

NHTSA complaint #10823319 — an unverified report by a vehicle owner.

at 250,000 miles Emporia, VA Crash 1 injured

AIR BAGS

I WAS TRAVELING EAST THRO AN INTERSECTION WHEN A TRUCK ON THE MY RIGHT RAMMED ME IN THE FRONT RIGHT SIDE OF MY CAR.I FELT THE CAR SPIN AND THE TRUCK ENDED UP IN MY RIGHT REAR BUMPER AND WHEN I CAME TO A STOP BOTH AIRBAGS DEPLOYED AND I WAS INJURED AND THE AIRBAGS EXPLODED AND I HAVE EYE DAMAGE TO MY RIGHT EYE AND NECK INJURY AND BACK INJURY. STILL SEEING SPINE DR. AND EYE DR EVERY 6 MONTHS.

NHTSA complaint #10722109 — an unverified report by a vehicle owner.

at 250,000 miles Emporia, VA Crash 1 injured

STRUCTURE:BODY

I WAS TRAVELING EAST THRO AN INTERSECTION WHEN A TRUCK ON THE MY RIGHT RAMMED ME IN THE FRONT RIGHT SIDE OF MY CAR.I FELT THE CAR SPIN AND THE TRUCK ENDED UP IN MY RIGHT REAR BUMPER AND WHEN I CAME TO A STOP BOTH AIRBAGS DEPLOYED AND I WAS INJURED AND THE AIRBAGS EXPLODED AND I HAVE EYE DAMAGE TO MY RIGHT EYE AND NECK INJURY AND BACK INJURY. STILL SEEING SPINE DR. AND EYE DR EVERY 6 MONTHS.

NHTSA complaint #10722109 — an unverified report by a vehicle owner.

at 250,000 miles Emporia, VA Crash 1 injured

ENGINE

I WAS TRAVELING EAST THRO AN INTERSECTION WHEN A TRUCK ON THE MY RIGHT RAMMED ME IN THE FRONT RIGHT SIDE OF MY CAR.I FELT THE CAR SPIN AND THE TRUCK ENDED UP IN MY RIGHT REAR BUMPER AND WHEN I CAME TO A STOP BOTH AIRBAGS DEPLOYED AND I WAS INJURED AND THE AIRBAGS EXPLODED AND I HAVE EYE DAMAGE TO MY RIGHT EYE AND NECK INJURY AND BACK INJURY. STILL SEEING SPINE DR. AND EYE DR EVERY 6 MONTHS.

NHTSA complaint #10722109 — an unverified report by a vehicle owner.

at 114,000 miles Ashford, CT

FUEL/PROPULSION SYSTEM

TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS. THE CONTACT STATED THAT AFTER REFUELING, FUEL SPEW BACK OUT OF THE FILLER NECK. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO DID NOT OFFER ANY ASSISTANCE SINCE THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER: 12V388000 (FUEL SYSTEM, GASOLINE: STORAGE: TANK ASSEMBLY: FILLER PIPE AND CAP). THE FAILURE AND CURRENT MILEAGE WAS 114,000. UPDATED 10/16/12*LJ THE CONSUMER STATED THE FUEL FILLER NECK CORRODED UPDATED 10/19/2012

NHTSA complaint #10471862 — an unverified report by a vehicle owner.

Penfield, NY

TIRES

WE PURCHASED A COMPLETE SET OF GENERAL GRABBER HTS 235/75R16 FOR OUR CHEVY EXPRESS VAN AT DUNN TIRE ON 11/15/08. THEY WERE SUPPOSED TO HAVE A 60K WARRANTY. WE WENT IN FOR THE REQUIRED ROTATIONS AND NOTED THAT THE TREAD DIDN'T SEEM TO BE WEARING WELL. AT THE 20K MILE ROTATION IN JANUARY OF 2011, DUNN TIRE ACKNOWLEDGED THAT THE TIRES WERE NOT PERFORMING AS ADVERTISED AND TOLD US THAT THEY WOULD LIKELY NEED TO ADJUST THE TIRES ON A PRO-RATA BASIS AT THE NEXT ROTATION AT 25K MILES. IT IS OUR BELIEF THAT THE TIRES ARE DEFECTIVE IN SOME WAY. THE ORIGINAL TIRES ON OUR VAN LIVED UP TO THEIR 40K WARRANTY AND WE REPLACED WITH THESE GRABBER HTS TIRES AT 39747 MILES. OUR DRIVING HABITS ARE CONSERVATIVE AND WE HAVE NEVER HAD TO REPLACE TIRES AHEAD OF THE WARRANTY PERIOD. THE TREAD WAS SO BAD ON THESE GRABBER HTS TIRES THAT WE WERE UNABLE TO DRIVE OUR VAN ON SNOWY ROADS DURING THIS PAST WINTER. WE ALSO WERE CONCERNED ABOUT HYDROPLANING ON THE EXPRESSWAY WHEN WE DROVE THE VAN THROUGH HEAVY RAINS THIS PAST WEEKEND WHEN WE DROPPED OFF OUR DAUGHTER AT COLLEGE. WE BELIEVE THESE TIRES ARE HAZARDOUS AND THAT AN INVESTIGATION SHOULD BE INITIATED. IT'S INCONCEIVABLE THAT WE WOULD ONLY GET 25K MILES OUT OF A 60K TIRES. WE FEEL CHEATED AND REALLY DO NOT WANT ANOTHER SET OF GENERAL TIRES ON A PRO-RATA BASIS.

NHTSA complaint #10401305 — an unverified report by a vehicle owner.

at 18,580 miles Toledo, OH

SERVICE BRAKES, HYDRAULIC

2004 CHEVY EXPRESS 1500.

NHTSA complaint #10303324 — an unverified report by a vehicle owner.

at 35,000 miles Beverly Hills, MI

SERVICE BRAKES, HYDRAULIC

ABS ENGAGES AT SLOW SPEED, AT TAIL END OF BRAKING, EVEN ON DRY SURFACES. THIS HAS BEEN GOING ON FOR AT LEAST EIGHT MONTHS. STARTED SOMETIME IN EARLY SUMMER/LATE SPRING 2008.

NHTSA complaint #10263589 — an unverified report by a vehicle owner.

at 91,048 miles Dallas, TX

AIR BAGS

THE PASSENGER SIDE AIRBAG EMPLOYED WHEN THE VEHICLE WAS PARKED INSIDE THE SHOP. THE VEHICLE IS AVAILABLE FOR INSPECTION AT STANLEY CHEVROLET CELINA TX 972-382-3000 CONTACT GARY WERNER SERVICE MANAGER. THE VEHICLE OWNER IS RICK DIETEL OF AMERSOL INC. 214-503-9977.

NHTSA complaint #10262412 — an unverified report by a vehicle owner.

at 120,000 miles Carlisle, PA

VISIBILITY

THE WINDSHIELD WIPERS WILL NOT TURN OFF.

NHTSA complaint #10243339 — an unverified report by a vehicle owner.

at 166,000 miles Modesto, CA Fire

ELECTRICAL SYSTEM:WIRING:FUSES AND CIRCUIT BREAKERS

TL*THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 1500. THE VEHICLE CAUGHT FIRE INSIDE THE FUSE BOX AFTER BEING PARKED FOR FOUR DAYS. THE FIRE CAUSED DAMAGE TO THE FUSE BOX. AS OF DECEMBER 26, 2007, THE DEALER HAD NOT INSPECTED THE VEHICLE. THE PURCHASE DATE WAS UNKNOWN. THE CURRENT AND FAILURE MILEAGES WERE 166,000.

NHTSA complaint #10212854 — an unverified report by a vehicle owner.

at 21,719 miles Nashville, TN

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER

2004 CHEVROLET EXPRESS G-VAN ENGINE OVERHEATED CAUSING SMOKE TO COME FROM DRIVER CABINET AND ENGINE SHUT OFF. *KB THE CONSUMER EXPERIENCED THE PROBLEM ON 4 SEPARATE OCCASIONS. THE BRAKE MASTER CYLINDER WAS REPLACED.

NHTSA complaint #10164761 — an unverified report by a vehicle owner.

at 21,719 miles Nashville, TN

ENGINE AND ENGINE COOLING

2004 CHEVROLET EXPRESS G-VAN ENGINE OVERHEATED CAUSING SMOKE TO COME FROM DRIVER CABINET AND ENGINE SHUT OFF. *KB THE CONSUMER EXPERIENCED THE PROBLEM ON 4 SEPARATE OCCASIONS. THE BRAKE MASTER CYLINDER WAS REPLACED.

NHTSA complaint #10164761 — an unverified report by a vehicle owner.

Edina, MN

VISIBILITY:WINDSHIELD

WINDSHIELD IS FULL OF WHAT LOOKS LIKE SCRATCHES, BUT IT MUST BE IN LAMINATION (?), BECAUSE YOU CAN'T FEEL THEM ON EITHER THE INTERIOR OR EXTERIOR OF THE GLASS. GRADUALLY GETTING WORSE, CAUSING ANNOYING VISION THROUGH THE WINDSHIELD. NO REAL INCIDENT DATE, JUST GRADUALLY GETTING WORSE, SPREADING.

NHTSA complaint #10160002 — an unverified report by a vehicle owner.