2004 Chevrolet Express 3500
Only 16 complaints on file — too few for a fair verdict.
This verdict reflects complaint volume compared to this model's typical year. Recalls and safety issues below apply regardless of the verdict — always check them.
Only 16 complaints on file — too few for a fair verdict. The data below is complete but unranked.
- Complaints
- 16
- Recalls
- 0
- Investigations
- 0
- Top problem
- —
Too few to rank
None on file
None on file
Not enough data
Complaints per year
2004: 16 complaints
View as data table
| Year | Complaints |
|---|---|
| 1997 | 2 |
| 1998 | 3 |
| 1999 | 4 |
| 2000 | 4 |
| 2001 | 11 |
| 2002 | 3 |
| 2003 | 12 |
| 2004 | 16 |
| 2005 | 17 |
| 2006 | 15 |
| 2007 | 11 |
| 2008 | 11 |
| 2009 | 9 |
| 2010 | 4 |
| 2012 | 5 |
| 2013 | 1 |
| 2014 | 1 |
| 2019 | 2 |
| 2021 | 1 |
| 2024 | 2 |
Known problem areas
Only 16 complaints on file for this model year — too few to rank by share. Raw counts only, below.
Service brakes
5 of 16 total reports mention: service brakes, most commonly citing hydraulic.
Steering
4 of 16 total reports mention: steering, most commonly citing idler and attachment.
Show complaint excerpts
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.
NHTSA ODI report, 2013-07-14
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.
NHTSA ODI report, 2007-08-31
Structure
3 of 16 total reports mention: structure, most commonly citing hinge and attachments and door.
Show complaint excerpts
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.
NHTSA ODI report, 2007-10-13
Fuel system, gasoline
3 of 16 total reports mention: fuel system, gasoline, most commonly citing filler pipe and cap.
Show complaint excerpts
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.
NHTSA ODI report, 2012-07-02
Dangerous as gas tank rusted through on top and left side after only rougly 100,000 miles.
NHTSA ODI report, 2012-04-10
Tires
1 of 16 total reports mentions: tires.
Safety timeline
No recalls on file for this model year.
0 recalls · 0 investigations · oldest first
To check one car, enter its VIN on the NHTSA recall page. Check a VIN →
Buy-smart checklist
2004 Chevrolet Express 3500 — pre-purchase inspection
Inspect
- Service brakes: 5 reports on file for this year.
- Steering: 4 reports on file for this year.
- Structure: 3 reports on file for this year.
FAQ
- Is the 2004 Chevrolet Express 3500 reliable?
- There isn't enough NHTSA complaint data on file yet to give this model year a verdict.
- What are the most common problems with the 2004 Chevrolet Express 3500?
- The most-reported component is service brakes, accounting for 31% of complaints on file.
- How many recalls does the 2004 Chevrolet Express 3500 have?
- No recalls are on file for this model year.
Data updated 2026-11-01 · Complaints are unverified owner reports filed with NHTSA, not independently verified defects. Methodology.