Owners have filed 18 complaints
about the 2004 Chevrolet Express 3500 with NHTSA between 2006 and 2016.
The largest single group is the brakes.
Across this model's run it ranks 6 of 8 worst.
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.
The dashed ring is 50 — the national norm. Further out is worse.
Complaint volume — 58
Against the median year of the Chevrolet Express 3500. 50 means typical for this
model; 100 means roughly double.
Severity — 29
5.6% of these complaints
involved a crash, fire, injury or death, against a national rate of
9.7%.
Early failure — 32
19% 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 3500
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 3500
Every complaint is filed against a part. Follow any row for the complaints about that part alone.
Brakes
527.8%
Median failure at 50,000 miles
Fuel & Propulsion
422.2%
Median failure at 117,000 miles
Steering
422.2%
0 crashes, 1 fires · median 60,000 mi
Body & Structure
316.7%
Median failure at 25,000 miles
Stability & Traction Control
15.6%
Median failure at 50,000 miles
Tires
15.6%
Median failure at 120,187 miles
When it fails
Odometer readings owners gave when they filed. About half of all
complaints include one.
1,000 – 9,999 miles
16.3%
25,000 – 49,999 miles
531.3%
50,000 – 74,999 miles
425.0%
100,000 – 149,999 miles
425.0%
150,000+ miles
212.5%
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.
Aug 2006peak 3Apr 2016
Complaints that involved harm
Reports where the owner recorded a crash, a fire, an injury or a death.
at 200,000 milesCamden, MIFire
STEERING
ON JUNE 08, 2013 MY HUSBAND HAD PARKED THE VAN ALONG SIDE THE ROAD - HE WAS OUT OF IT WORKING. THE VEHICLE WAS NOT RUNNING - WHEN A COWORKER NOTICED SMOKE COMING FROM THE VAN. THE COWORKER RAN OVER TO THE VAN AND SEEN THAT THE FIRE WAS IN THE STEERING COLUMN. WITHIN MINUTES THE ENTIRE VAN WAS ON FIRE. MY CONCERN IS THAT THIS VAN HAD BEEN HAVING ISSUES WITH SOMETHING SECURITY. ALL OF THE GAUGES WOULD SHUT DOWN AND IT WOULD DISPLAY "SECURITY " ON THE DASH. I PERSONALLY HAD CONTACTED OUR LOCAL CHEVY DEALER TO INQUIRE ABOUT THIS PROBLEM AND HOW TO TAKE CARE OF IT. THE LOCAL DEALER SUGGESTED A NEW KEY MADE AT THE DEALERSHIP USING THE VIN NUMBERS. THIS MADE NO DIFFERENCE AS IT HAPPENED AGAIN. THIS TIME MY HUSBAND WENT TO A DEALERSHIP IN NORWALK, OHIO INQUIRING ABOUT THE PROBLEM - THEY HAD NO IDEA WHAT THE SOLUTION WAS EITHER. MY CONCERN IS THAT THE DEALERSHIPS HAVE NO IDEA WHAT THE "SECURITY" IS OR HOW TO FIX IT......ALSO I AM WONDERING IF THIS "SECURITY" ISSUE IS THE REASON THAT I LOST MY VAN TO THE FIRE ON JUNE 08, 2013. I CONTACTED GM BUT THEY BLEW ME OFF SAYING I HAD OWNED THE VEHICLE TOO LONG TO GET ANY MONEY FOR MY LOSS. THESE VANS ARE DESIGNED TO CARRY LOTS OF PEOPLE AND IF MY FAMILY HAD BEEN IN THIS VEHICLE AT THE TIME OF THE FIRE THERE WOULD NOT HAVE BEEN ENOUGH TIME TO GET EVERYONE OUT SAFELY AND THAT WORRIES ME GREATLY.
NHTSA complaint #10524779 — an unverified report by a vehicle owner.
The most recent complaints
In the owners' own words, exactly as filed with NHTSA.
at 43,997 milesHana, HI
SERVICE BRAKES
2004 CHEVROLET EXPRESS COLLINS SCHOOL BUS WHILE DRIVING AT 15 MPH ON AN INCLINED RURAL COUNTRY ROAD ATTEMPTING TO BRAKE NOTICED PEDAL EXTENDED TO THE FLOOR AND WAS STOPPED BY FURTHER DOWN SHIFTING AND APPLYING EMERGENCY BRAKE. INFORMED BY REPAIR SHOP THE RIGHT FRONT HYDRAULIC LINE RUBBED THROUGH THE METAL BRAKE LINE CAUSING THE FAILURE. FAILURE MILEAGE 43,997.
NHTSA complaint #10854900 — an unverified report by a vehicle owner.
at 120,187 milesSublimity, OR
TIRES
TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 3500 EQUIPPED WITH TOYO OPEN COUNTRY H/T TUFF DUTY TIRES, SIZE: LT245/75/R16 TIRES. WHILE DRIVING 65 MPH, THE CONTACT HEARD A LOUD NOISE AND THE REAR DRIVER SIDE TIRE BLEW OUT. THE VEHICLE WAS TOWED TO A DEALER WHO DIAGNOSED THAT ALL FOUR TIRES HAD CRACKS AND NEEDED TO BE REPLACED. IN ADDITION, MULTIPLE PARTS NEEDED TO BE REPLACED. THE TIRES WERE REPLACED, BUT THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE FAILURE MILEAGE WAS 120,187 AND THE TIRE FAILURE MILEAGE WAS 25,982.
NHTSA complaint #10761661 — an unverified report by a vehicle owner.
at 25,000 milesGreenwich, CT
STRUCTURE:BODY:DOOR:HINGE AND ATTACHMENTS
TL* 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 — an unverified report by a vehicle owner.
at 25,000 milesGreenwich, CT
STRUCTURE:BODY:DOOR
TL* 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 — an unverified report by a vehicle owner.
at 128,000 milesSyracuse, UT
SERVICE BRAKES
TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 3500. THE CONTACT STATED WHILE DRIVING DOWN A MOUNTAIN ROAD APPROXIMATELY 45 MPH THE BRAKE PEDAL WAS DEPRESSED AND THE VEHICLE BEGAN TO VIBRATE EXCESSIVELY AND THE BRAKE DISCS OVERHEATED. THE FAILURE WAS NOT DIAGNOSED NOR WAS THE VEHICLE REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE DEFECT. THE APPROXIMATE FAILURE MILEAGE WAS 128,000. UPDATED 08/11/14*LJ UPDATED 08/18/2014
NHTSA complaint #10593709 — an unverified report by a vehicle owner.
at 130,000 milesHighland, IN
FUEL/PROPULSION SYSTEM
TL* 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 — an unverified report by a vehicle owner.
at 200,000 milesCamden, MIFire
STEERING
ON JUNE 08, 2013 MY HUSBAND HAD PARKED THE VAN ALONG SIDE THE ROAD - HE WAS OUT OF IT WORKING. THE VEHICLE WAS NOT RUNNING - WHEN A COWORKER NOTICED SMOKE COMING FROM THE VAN. THE COWORKER RAN OVER TO THE VAN AND SEEN THAT THE FIRE WAS IN THE STEERING COLUMN. WITHIN MINUTES THE ENTIRE VAN WAS ON FIRE. MY CONCERN IS THAT THIS VAN HAD BEEN HAVING ISSUES WITH SOMETHING SECURITY. ALL OF THE GAUGES WOULD SHUT DOWN AND IT WOULD DISPLAY "SECURITY " ON THE DASH. I PERSONALLY HAD CONTACTED OUR LOCAL CHEVY DEALER TO INQUIRE ABOUT THIS PROBLEM AND HOW TO TAKE CARE OF IT. THE LOCAL DEALER SUGGESTED A NEW KEY MADE AT THE DEALERSHIP USING THE VIN NUMBERS. THIS MADE NO DIFFERENCE AS IT HAPPENED AGAIN. THIS TIME MY HUSBAND WENT TO A DEALERSHIP IN NORWALK, OHIO INQUIRING ABOUT THE PROBLEM - THEY HAD NO IDEA WHAT THE SOLUTION WAS EITHER. MY CONCERN IS THAT THE DEALERSHIPS HAVE NO IDEA WHAT THE "SECURITY" IS OR HOW TO FIX IT......ALSO I AM WONDERING IF THIS "SECURITY" ISSUE IS THE REASON THAT I LOST MY VAN TO THE FIRE ON JUNE 08, 2013. I CONTACTED GM BUT THEY BLEW ME OFF SAYING I HAD OWNED THE VEHICLE TOO LONG TO GET ANY MONEY FOR MY LOSS. THESE VANS ARE DESIGNED TO CARRY LOTS OF PEOPLE AND IF MY FAMILY HAD BEEN IN THIS VEHICLE AT THE TIME OF THE FIRE THERE WOULD NOT HAVE BEEN ENOUGH TIME TO GET EVERYONE OUT SAFELY AND THAT WORRIES ME GREATLY.
NHTSA complaint #10524779 — an unverified report by a vehicle owner.
at 39,000 milesToledo, IL
FUEL SYSTEM, GASOLINE
TL* 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 — an unverified report by a vehicle owner.
at 170,000 milesLawrenceburg, IN
FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP
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. THE REPLACEMENT PART IS NOW PLASTIC. SO GM MUST HAVE RECOGNIZED THE PROBLEM (BUT FAILED TO RECALL) AND CHANGED THE PIPE TO A RUST-PROOF MATERIAL.
NHTSA complaint #10463960 — an unverified report by a vehicle owner.
at 104,000 milesGreen BAY, WI
FUEL SYSTEM, GASOLINE
DANGEROUS AS GAS TANK RUSTED THROUGH ON TOP AND LEFT SIDE AFTER ONLY ROUGLY 100,000 MILES.
NHTSA complaint #10454780 — an unverified report by a vehicle owner.
at 66,445 milesWaterford, MI
SERVICE BRAKES, HYDRAULIC
TL*THE CONTACT OWNS A 2004 CHEVROLET CARGO EXPRESS VAN 3500. WHILE DRIVING 45 MPH HE HAD ATTEMPTED TO BRAKE AND NOTICED THAT THE BRAKE PEDAL EXTENDED TO THE FLOOR AND THE VEHICLE COULD ONLY BE STOPPED BY MANUALLY DOWN SHIFTING THE GEARS. THE DEALER INFORMED THE CONTACT THAT THE COOLANT LINE RUBBED THROUGH TO THE BRAKE LINE. THERE WAS A BURNING SMELL PRIOR TO THE FAILURE IN THE FRONT AXLE AREA OF THE VEHICLE. THE CURRENT AND FAILURE MILEAGES WERE 66445.
NHTSA complaint #10281151 — an unverified report by a vehicle owner.
at 50,000 milesHomer City, PA
SERVICE BRAKES, HYDRAULIC
THE BRAKES ON MY 2004 CHEVY EXPRESS 3500 ACTIVATE WITHOUT WARNING, STOPPING THE VEHICLE IN TRAFFIC. A WARNING LIGHT INDICATED A FAILURE OF THE STABILITY CONTROL SYSTEM. FAULT CODE C0196 WAS RECORDED. MY DEALER REPLACED THE ELECTRONIC BRAKE CONTROL MODULE, BUT THE PROBLEM CONTINUES TO OCCUR. I WAS ALMOST REAR-ENDED WHEN THE VEHICLE STOPPED WITHOUT WARNING IN TRAFFIC.
NHTSA complaint #10275040 — an unverified report by a vehicle owner.
at 50,000 milesHomer City, PA
ELECTRONIC STABILITY CONTROL (ESC)
THE BRAKES ON MY 2004 CHEVY EXPRESS 3500 ACTIVATE WITHOUT WARNING, STOPPING THE VEHICLE IN TRAFFIC. A WARNING LIGHT INDICATED A FAILURE OF THE STABILITY CONTROL SYSTEM. FAULT CODE C0196 WAS RECORDED. MY DEALER REPLACED THE ELECTRONIC BRAKE CONTROL MODULE, BUT THE PROBLEM CONTINUES TO OCCUR. I WAS ALMOST REAR-ENDED WHEN THE VEHICLE STOPPED WITHOUT WARNING IN TRAFFIC.
NHTSA complaint #10275040 — an unverified report by a vehicle owner.
at 60,000 milesPewaukee, WI
STEERING
TL*THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 3500. WHILE DRIVING APPROXIMATELY 35 MPH, THE VEHICLE SUDDENLY LOST POWER STEERING AND BRAKING ABILITY. SHE LOST CONTROL OF THE VEHICLE. SHE SHIFTED INTO A LOWER GEAR AND WAS ABLE TO COMPLETELY STOP THE VEHICLE. THE CONTACT WAS ABLE TO TURN OFF AND RESTART THE VEHICLE. THE VEHICLE WAS TAKEN TO NUMEROUS DEALERS AND SHOPS, BUT THEY ALL CONFIRMED THAT THE HYDRO BOOST FAILED. THERE WAS A RECALL, IN WHICH THE VEHICLE WAS NOT INCLUDED. NO RECALL COULD BE FOUND FOR THE CHEVROLET EXPRESS 3500 ON THE NHTSA WEBSITE. THE CONTACT BELIEVED THAT IF THE FAILURE WAS COMMON, A RECALL SHOULD BE ISSUED. THE CURRENT AND FAILURE MILEAGES WERE 60,000.
NHTSA complaint #10250646 — an unverified report by a vehicle owner.
Ashford, CT
STEERING:LINKAGES:ARM:IDLER AND ATTACHMENT
2004 CHEVY EXPRESS WITH BROKEN STEERING IDLER. CONSUMER IS PLEASED BECAUSE THE DEALER FIXED THE PROBLEM. *KB **NAR**
NHTSA complaint #10210496 — an unverified report by a vehicle owner.
Syracuse, NY
STRUCTURE:BODY:DOOR:HINGE AND ATTACHMENTS
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 — an unverified report by a vehicle owner.
at 39,000 milesAshford, CT
STEERING
TL*THE CONTACT OWNS A 2004 CHEVROLET EXPRESS 3500. WHILE DRIVING 5-10 MPH, THE CONTACT HEARD A CLUNKING NOISE AND THE STEERING BECAME DIFFICULT. THE DEALER STATED THAT THE STEERING IDLER ARM WAS CRACKED. THE MANUFACTURER DENIED THE REPAIR AS PART OF RECALL NUMBER 07103 BECAUSE THE CRACK ON THE IDLER ARM WAS NOT LOCATED IN THE CORRECT SPOT. THE FAILURE MILEAGE WAS 39,000 AND CURRENT MILEAGE WAS 46,000. UPDATED 10/09/07.
NHTSA complaint #10201318 — an unverified report by a vehicle owner.
at 9,800 milesOcala, FL
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:ROTOR
DT*: THE CONTACT STATED WHILE DRIVING ON THE HIGHWAY AT VARIOUS SPEEDS FOR AN EXTENDED PERIOD OF TIME WITH BRAKES DEPRESSED, THE STEERING WHEEL VIOLENTLY SHOOK. THE VEHICLE WAS INSPECTED BY A DEALER WHO TURNED THE BRAKE ROTORS. AFTERWARDS, THE PROBLEM PERSISTED. THE VEHICLE WAS TAKEN BACK TO THE DEALER WHO AS UNABLE TO DUPLICATE THE PROBLEM. THE MANUFACTURER WAS CONTACTED.
NHTSA complaint #10164314 — an unverified report by a vehicle owner.