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Resources for the Repair and Maintenance of your 2004 Chevrolet Express 2500

2004 Chevrolet Express 2500

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2004 Chevrolet Express 2500 Problems

Electrical & Lights -- Verified

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.

Miscellaneous -- Verified

Various electrical components under the front carpet/rubber mat may become damaged if excess water is used to clean the rear cargo area.

Heating & Air Conditioning -- Verified

Extended life coolant may become contaminated and require cooling system service before the recommended 100,000 miles.

Electrical & Lights -- Verified

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.

Miscellaneous -- Verified

Our technicians recommend flushing the brake fluid every 60,000 miles.  Brake fluid that is dirty may cause problems in the brake system.

2004 Chevrolet Express 2500 Recalls (Recent)

Body, Interior & Misc., March 15, 2006

RepairPal Expert Overview:

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.

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Body, Interior & Misc., May 7, 2004

RepairPal Expert Overview:

Some vans may have been produced with seat belt assemblies containing a latch with a brittle condition that may not withstand the forces specified by the standards. This may mean the belt would not restrain the seat occupants as needed in a crash. Dealers will replace the safety belt buckle. The recall began May 7, 2004. The GM recall number is 04025.

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Brakes, March 23, 2005

RepairPal Expert Overview:

On vehicles equipped with the Bosch hydraulic brake booster, the boost pressure accumulator may crack and break away from the hydro-boost assembly during normal operation. If this were to happen while the hood is open, fragments from the accumulator could injure people standing in the immediate area. The loss of fluid while driving would cause increased steering and braking effort and a crash could occur without warning. Dealers will test the hydro-boost assembly for function of the two-function valve. If the hydro-boost assembly fails the test, it will be replaced free of charge. The recall began March 23, 2005. The GM recall number is 05006.

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Brakes, June 18, 2004

RepairPal Expert Overview:

The hydro-boost housing relief valve bore may be out of specification. The seal may fracture as a result, which may reduce braking assist and slightly increase the steering effort while braking. Under certain conditions, more braking effort will be required to stop the vehicle. Dealers will replace the hydro-boost relief valve. The recall began June 18, 2004. The GM recall number is 04004.

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Drive Train, August 19, 2004

RepairPal Expert Overview:

The cable for the transmission shift lever may separate, meaning the transmission shift lever position and the transmission indicator may no longer correlate. If this were to occur, the vehicle may not move in the expected direction. Dealers will inspect the transmission shift cable assembly and replace it if needed. The recall began August 19, 2004. The GM recall number is 04061.

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2004 Chevrolet Express 2500 Questions and Answers

nextechjack, 2004 Chevrolet Express 2500, 4.8L V8, Rancho Palos Verdes, CA

I hear a higher pitch whine coming from engine compartment.Only when in gear and get louder as i increase revs. Also the A/C comes out so cole it put frost on the window and this was while it was o...

stalin77, 2004 Chevrolet Express 2500, 4.3L V6, Philadelphia, PA

how can i fix filed TCC solenoid on chevy express 2500 2004

Iffkin, 2004 Chevrolet Express 2500, 5.3L V8, Aurora, CO

Hi!
I have 2004 Chevy Express AWD. There is app. 80 000 miles driven with this car.
Recently local service center did full oil change (axles, gearbox, intermediate box and engine), as well they cha...

ufixit, 2004 Chevrolet Express 2500, 4.8L V8, Oxford, MI

the battery indicator light will flash on and off. Its been doing it for over a year. Did system check. alternator, starter and battery all check out fine. No problems charging or running. The bat...

ufixit, 2004 Chevrolet Express 2500, 4.8L V8, Oxford, MI

I get flashing P0300 flashing code when driving above 60+ mph. New plus and wires, No problems with start, idle or excelleration, vacum checks ok, yet when I use Actron scanner to clear code and l...

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2004 Chevrolet Express 2500 Reviews

GREAT PASSENGER VAN WITH OVER 100K. HAVE HAD TO REPLACE WATER PUMP TWICE. NOT SO CHEAP. ELECTRICAL WIRING SYSTEM POORLY DESIGNED ACCESS. INTERIOR LIGHT SWITCH PROBLEM ALONG WITH REAR BACK-UP LIGHT FAILURE. I REALLY LIKE THIS VAN. WITH ITS SMALL PROBLEMS.

I have had several Express vans over the years. This one and the others all had problems with the rear a/c lines leaking due to the way they are mounted. The other main problem is the side door hinges seize up due to rust, and yes I kept them lubricated. Both of these problems have been occurring for several years and are expensive repairs if completed at a dealer. These design problems should have been addressed by GM years ago.

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