2004 Chevrolet Express 3500 Recalls
No NHTSA recalls on record for the 2004 Chevrolet Express 3500. That means NHTSA has no open safety campaign for this vehicle — it does not guarantee the absence of problems. Owners have filed 18 complaints with NHTSA, most often about the steering. Last updated July 5, 2026.
Complaints by component
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal information removed.
“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…”
“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…”
“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…”
“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…”
“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…”
“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…”
“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…”
“Dangerous as gas tank rusted through on top and left side after only rougly 100,000 miles. *tr”
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL, FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 2004 Chevrolet Express 3500 as of July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page contains ads and affiliate links. Full methodology.