2004 Chevrolet Express 2500 Repair and Maintenance
A guide to problems, costs, maintenance and repair for your 2004 Chevrolet Express 2500
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2004 Chevrolet Express 2500 ProblemsFuel Level Sensor Failure
It is common for the fuel level sensor in the fuel tank read the fuel level incorrectly. The sensor must be replaced to correct the condition. Our technicians recommend having the complete fuel pump module replaced on high mileage vehicles.
The tail light wiring harness in the cargo area is not protected very well. As a result it may become damaged due to normal wear a tear. This damage can causing some or all of the rear lights to stop working.
2004 Chevrolet Express 2500 QuestionsWhere is the thermostat located and even further, how do you change the thermostat? (2 answers)
Van has been over heating on an irregular basis with pools of coolant sporadically being left under van. Pretty sure it's a bad thermostat but fearful it's also the water pump.
Changed tank and sender as well as the crank shaft sensor still crank with no start. Not sure where o look next
2004 Express van 4.8l with 140k miles.
Past couple years:
Hard to start after fuel fill up.
Random miss and hesitation when accelerating. Pumping throttle would cure. Then randomly again from 30 min to 7 days between.
Missing most of the time, especially when hot. Rough idle and...
2004 Chevrolet Express 2500 RecallsFuel Leak Due to Corrosion in Area Near Gas Cap
On vehicles equipped with a left side cargo door, water and road contaminants may become trapped in the protective conduit that covers the fuel filler pipe, which can cause the pipe to corrode. Significant corrosion may allow fuel to leak during refueling, and in the presence of an ignition source, this could cause a fire. Dealers will install a new fuel filler neck to correct this concern. The General Motors recall number is 12166.
On certain vans, the front and rear seat belts will not latch or unlatch. In a crash, the risk of injury is increased if the seat occupant is not properly restrained. Dealers will inspect the seat belt buckles, and will replace the buckle assembly if the buckle is found to be inoperative. If the buckle is found to function, only the upper buckle cover will be replaced. The recall began March 15, 2006. The GM recall number is 05113.
On two vehicles, the high mount (third) brake lens may not reflect enough light to meet Federal standards. Following vehicles may not adequately see the brake lamps, increasing the risk of a rear-end crash. Quality Coaches is working with Audiovox to replace the center high-mounted brake lamp assembly. The recall began November 23, 2005. The Quality/ASA recall number is VCCBLCHV.