2004 Chevrolet Express 3500 Repair and Maintenance
A guide to problems, costs, maintenance and repair for your 2004 Chevrolet Express 3500
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2004 Chevrolet Express 3500 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.
One or both secondary air injection check valves may become restricted causing poor air flow resulting in illumination of the Check Engine Light. It is often recommend to replace both check valves even if a fault code is set for only one bank of cylinders. Replacing only one valve may result in a return trip to the repair shop.
2004 Chevrolet Express 3500 QuestionsHave a 04 3500 6.0 that skips after cutting it off & restarting within a few min (1 answer)
This is heat related and I have tried changing multiple things. Plugs, wires, coil packs, Cam PS, injectors, MAP, TPS, IAC, still same result. I can play with the throttle (on & off real quick) and it will clear up and run fine, unless I go somewhere and cut it off and get back in within a fe...
I have changed the fuses and nothing they still don't work and it all started when I took it to a mechanic like a month ago so he could fix a problem I had with the van and he fixed it but now the dashboard lights won't work
when you start the van it idles very high continuous. code po137.
2004 Chevrolet Express 3500 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 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.