2004 Chevrolet Express

Defect. General Motors (GM) is recalling certain model year 2003-2004 Chevrolet Express and GMC Savana vehicles, equipped with a left side cargo door, and originally sold or currently registered in Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin, and the District of Columbia. Water and road contaminants may become trapped in the protective conduit that covers the fuel filler pipe and may cause the pipe to corrode.

Risk. Significant corrosion may allow fuel to leak during refueling, and in the presence of an ignition source; there is an increased risk of fire.

Remedy. GM will notify owners, and dealers will install a new fuel filler neck, free of charge. The safety recall began on October 1, 2012. Owners may contact the Chevrolet owner center at 1-866-694-6546 and GMC at 1-866-996-9463.

Defect. SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.

Risk. DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy. SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON MAY 11, 2009. OWNERS MAY CONTACT SABERSPORT AT 1-909-598-7589.

Defect. ON CERTAIN FULL-SIZE PASSENGER, CARGO, OR CUTAWAY VANS, THE FRONT AND REAR SEAT BELT BUCKLES WILL NOT LATCH OR WILL NOT UNLATCH.

Risk. IN THE EVENT OF A CRASH, A SEAT OCCUPANT MAY NOT BE PROPERLY RESTRAINED INCREASING THE RISK OF PERSONAL INJURY.

Remedy. DEALERS WILL INSPECT THE BUCKLES AND, IF FOUND TO BE INOPERATIVE, THE ENTIRE BUCKLE ASSEMBLY WOULD BE REPLACED. FOR BUCKLES FOUND TO BE OPERATIVE, DEALER WILL REPLACE ONLY THE UPPER BUCKLE COVER. THE RECALL WILL BE CONDUCTED IN PHASES. THE FIRST PHASE MAILING BEGAN DURING MARCH 2006. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438 OR GMC AT 1-866-996-9463.

Defect. CERTAIN TRUCKS, SPORT UTILITY VEHICLES, AND VANS EQUIPPED WITH BOSCH HYDRO-BOOST BRAKE ASSEMBLIES, THE HYDRAULIC BRAKE BOOSTER PRESSURE ACCUMULATOR MAY CRACK AND SEPARATE FROM THE HYDRO-BOOST ASSEMBLY DURING NORMAL OPERATING CONDITIONS.

Risk. IF A SEPARATION OCCURRED AND THE HOOD OF THE VEHICLE WERE OPEN, FRAGMENTS FROM THE ACCUMULATOR COULD CAUSE INJURY TO PEOPLE IN THE IMMEDIATE AREA. THE PRESENCE OF THIS CRACK OR FRACTURED SURFACE COULD ALLOW THE HYDRAULIC FLUID TO LEAK FROM THE ACCUMULATOR CIRCUIT OF THE BOOSTER ASSEMBLY. THE LOSS OF FLUID WOULD CAUSE INCREASED STEERING AND BRAKING EFFORT AND A CRASH MAY OCCUR WITHOUT PRIOR WARNING.

Remedy. DEALERS WILL TEST THE HYDRO-BOOST ASSEMBLY FOR FUNCTIONAL OPERATION OF THE TWO-FUNCTION VALVE. IF THE HYDRO-BOOST ASSEMBLY FAILS THE TEST, DEALERS WILL REPLACE THE ASSEMBLY FREE OF CHARGE. THE RECALL BEGAN ON MARCH 23, 2005. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438, GMC TRUCKS AT 1-866-996-9463 AND HUMMER AT 1-800-732-5493.

Defect. CERTAIN VANS WERE BUILT WITH A TRANSMISSION SHIFT CABLE ASSEMBLY THAT MAY SEPARATE. IF THE CABLE ASSEMBLY SEPARATES, THE TRANSMISSION SHIFT LEVER POSITION AND THE TRANSMISSION INDICATOR MAY NO LONGER CORRELATE.

Risk. IF THIS WERE TO OCCUR, THE VEHICLE COULD MOVE IN A DIRECTION NOT ANTICIPATED BY THE DRIVER, WHICH COULD RESULT IN A VEHICLE CRASH.

Remedy. DEALERS WILL INSPECT THE TRANSMISSION SHIFT CABLE ASSEMBLY, AND IF NECESSARY, REPLACE IT. THE RECALL BEGAN ON AUGUST 19, 2004. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438 OR GMC AT 1-866-996-9463.

Defect. CERTAIN VANS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 209, "SEAT BELT ASSEMBLIES." THESE VEHICLES MAY HAVE BEEN PRODUCED WITH SEAT BELT BUCKLE ASSEMBLIES CONTAINING A LATCH WITH A BRITTLE CONDITION THAT MAY NOT WITHSTAND THE FORCE REQUIREMENTS OF THE STANDARD.

Risk. THE SAFETY BELT MAY NOT RESTRAIN THE OCCUPANT AS INTENDED DURING A CRASH, WHICH COULD RESULT IN INJURY TO THE OCCUPANT.

Remedy. DEALERS WILL REPLACE THE SAFETY BELT BUCKLE. THE RECALL BEAGN MAY 7, 2004. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438 OR GMC AT 1-866-996-9463.

Defect. CERTAIN SPORT UTILITY VEHICLES, PICKUP TRUCKS, AND PASSENGER VANS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 135, ?PASSENGER CAR BRAKE SYSTEMS.? SOME OF THESE VEHICLES WERE PRODUCED WITH AN OUT-OF-SPECIFICATION BRAKE HYDRO-BOOST HOUSING RELIEF VALVE BORE.

Risk. CONSEQUENTLY, THE VALVE O-RING SEAL MAY FRACTURE. STEERING EFFORTS MAY BE SLIGHTLY INCREASED WHILE BRAKING OR PARKING. UNDER CERTAIN DRIVING CONDITIONS, A FRACTURED SEAL MAY REQUIRE A SLIGHT INCREASE IN THE APPLIED BRAKE PEDAL EFFORT TO ACHIEVE THE SAME VEHICLE DECELERATION RATE AS PRIOR TO THE SEAT FRACTURE.

Remedy. DEALERS ARE TO REPLACE THE HYDRO-BOOST RELIEF VALVE. THE RECALL BEGAN ON JUNE 18, 2004. OWNERS SHOULD CONTACT CADILLAC AT 1-866-982-2339; CHEVROLET AT 1-800-630-2438; GMC AT 1-866-996-9463; OR HUMMER AT 1-866-486-6376.

NHTSA Campaign Number: 12V388000. I have this problem. A leaking fuel line due to corrosion. I drive in the Cascade MT's of Washington state. my line now leaks excessively on fill up.

This vehicle was sold for use over US highways, as "repairable condition". After going to a mechanic shop, I was advised, because of sever rust the rear leaf spring hangers were completely rusted thru, the rear axle assembly could come off or the frame could break in half, by just going over say, a railroad crossing. The mechanic said they would not repair this vehicle for use to drive on roads. I am requesting a local representative to help evaluate if this vehicle is safe to travel on Oklahoma roads.

TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS. WHILE THE VEHICLE WAS STATIONARY, FUEL SPILLED ONTO THE GROUND. IT WAS DIAGNOSED THAT THE FILLER NECK WAS CORRODED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE. THE FAILURE MILEAGE WAS 148,000. UPDATED 04/11/2017*JS

TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS. WHILE THE VEHICLE WAS PARKED THE REAR DRIVER'S SIDE WINDOW FELL OUT OF PLACE. THE CONTACT STATED THAT ALL THE WINDOWS ON THE VEHICLE WERE LOOSE. THERE NO WARNING LIGHTS ILLUMINATED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE ISSUE. THE FAILURE MILEAGE WAS 33,000. UPDATED 01/31/17*LJ CONSUMER STATED DRIVERS SIDE REAR SEAT LOWER WINDOW BROKE. GLUE CAME OFF MANUFACTURED WINDOW MADE BY C.R. LAURENCE CO, INC. WINDOW WAS REPLACED 11/08/16. UPDATED 6/22/18*JB

THE VAN WAS PARKED IN MY DRIVEWAY STATIONARY. IT CAUGHT FIRE AND PROCEEDED TO BURN COMPLETELY FOR UNKNOWN REASONS. THE WEBSITE STATES THIS VIN NUMBER IS NOT INCLUDED IN ANY RECALLS BUT THE VEHICLE TYPE HAS A RECALL LISTED THAT STATES IT COULD BE A FIRE HAZARD.

TWO REAR BUCKET SEAT BELT CABLES HAVE BROKEN WITHOUT IMPACT.

ENGINE EXHAUST MANIFOLD BROKEN BOLTS,HAS 3 AT THIS POINT AND TIME. THIS CAUSES THE EXHAUST TO LEAK INTO DRIVERS COMPARTMENT. *TR

TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS. THE CONTACT STATED THAT WHILE ATTEMPTING TO SHIFT INTO PARK, THE LINKAGE POPPED OFF PREVENTING THE VEHICLE FROM BEING SHIFTED INTO PARK. THE EMERGENCY BRAKE WAS ENGAGED IN ORDER TO PREVENT THE VEHICLE FROM MOVING. THE VEHICLE WAS DIAGNOSED WITH A FAILED CABLE ASSEMBLY THAT NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 120,000 AND THE CURRENT MILEAGE WAS 136,000.

TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS. THE CONTACT STATED THAT WHILE DRIVING 5 MPH AND DEPRESSING THE BRAKE PEDAL, THE ABS SYSTEM PREVENTED THE VEHICLE FROM BRAKING PROPERLY AND THE ABS WARNING LIGHT ILLUMINATED. IN ONE OCCASION, THE VEHICLE FAILED TO STOP AND PROCEEDED THROUGH THE INTERSECTION DURING A RED LIGHT. THE VEHICLE WAS TAKEN TO A PRIVATE MECHANIC WHERE IT WAS DIAGNOSED THAT THE BRAKE SENSORS AND THE ABS MAIN CONTROL SYSTEM NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS REPAIRED BUT THE FAILURE RECURRED. THE FAILURE MILEAGE WAS 110,000 AND THE CURRENT MILEAGE WAS UNKNOWN.

TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS G1500. THE CONTACT STATED THAT THE DRIVER AND PASSENGER SIDE DOUBLE DOOR HINGES FAILED AND THE DOORS COULD NOT BE OPENED. THE DEALER ADVISED THAT THE DOOR HINGES NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 109,000 AND THE APPROXIMATE FAILURE MILEAGE WAS 110,00.

VEHICLE HAS CONTINUED TO EVIDENCE PROBLEMS SIMILAR TO WHAT'S DESCRIBED BY NHTSA CAMPAIGN ID NO. 04V452000. POWER STEERING PUMP AND BELTS HAVE BEEN REPLACED AND GM DEALER PERFORMED HYDRO BOOST INSPECTION TEST AND IT PASSED; SAID NO FURTHER ACTION REQUIRED. BUS HAS AGAIN LOST POWER STEERING AND BRAKES TO CAUSE A DANGEROUS CONDITION. DEALER SAYS IT IS NOT A VEHICLE THAT RECALL APPLIES TO. *JS

WHILE TRAVELING DOWN A STEEP GRADE WHILE APPLYING THE BRAKES, A SEVERE SHAKING OF THE STEERING WHEEL AND WHEELS OCCURRED. IT WAS SO SEVERE THE STEERING WHEEL SHOOK OUT OF MY HANDS. ONCE BACK ON LEVEL GRADE FOR A MILE OR SO, APPLYING THE BRAKES DIDN'T RESULT IN THE SEVERE SHAKING. FROM THAT POINT ON WHILE DRIVING ON ANY STEEP HILL OR MOUNTAIN, THE SAME THING OCCURS. THE BRAKE PADS AND ROTORS WERE REPLACED LAST YEAR, BUT THAT HAS NOT FIXED THE ISSUE.

MY ANTI-LOCK BRAKES ACTIVATE AT LOW SPEEDS. WE FIRST NOTICED IT AROUND 37,000 MILES, BUT NOW IT OCCURS ALMOST EVERY TIME WE APPLY THE BRAKES AT LOW SPEED AT 39,000 MILES. WE DISCUSSED THE PROBLEM WITH TWO CHEVY GARAGES - BOTH ADMITTED THAT IT WAS A COMMON, KNOWN CORROSION PROBLEM THAT REQUIRES EITHER CLEANING THE BRAKE SENSORS FOR APPROXIMATELY $200 OR REPLACING THEM AT A COST OF APPROXIMATELY $460. THIS IS A HUGE SAFETY ISSUE FOR US. THE VAN DRIFTS FORWARD TOO FAR WHEN WE STOP AND WE ARE CONCERNED THAT WE WILL EITHER HIT ANOTHER CAR OR POSSIBLY A PEDESTRIAN. WE ARE CONCERNED THAT THIS WILL BE AN ONGOING PROBLEM WITH THE VEHICLE AS WE ARE LOCATED IN NEW YORK STATE AND SALT IS A COMMON WINTER CORROSIVE. *TR

ON JUNE 20TH, 2008 WE BROUGHT OUR VAN IN FOR A ROUTINE BRAKE INSPECTION AND WHEEL ALIGNMENT AT 36,117 MILES. WE ALSO NOTICED A NOISE IN THE REAR WHEN MAKING A TURN. THE MECHANIC INDICATED THAT THE BRAKE BACKING PLATES ON BOTH SIDES WERE RUSTED, AND THE LEFT REAR BACKING PLATE WAS ROTTED TO THE POINT THAT IT HAD HOLES IN IT. THE MECHANIC INDICATED THAT THE REPLACEMENT PARTS WERE INEXPENSIVE, BUT THE LABOR WAS INTENSIVE AND WOULD PROBABLY COST IN THE NEIGHBORHOOD OF $600. WE HAVE NOT REPAIRED THE BACKING PLATES YET BECAUSE THIS VEHICLE HAS OTHER QUALITY ISSUES AND WE ARE CONSIDERING A REPLACEMENT VEHICLE. *TR

DT*: THE CONTACT STATED THE SEAT BELT BUCKLE DID NOT RELEASE THE SEAT BELT PROPERLY. INTERMITTENTLY, THE SEAT BELT BECAME STUCK IN THE BUCKLE. THE NOTICE FOR NHTSA RECALL #05V558000, PERTAINING TO THE SEAT BELTS, WAS RECEIVED. THE VEHICLE WAS TAKEN TO A SERVICE DEALER, WHERE THE DEALER DENIED A FREE REMEDY DUE TO THE PROBLEM ONLY BEING INTERMITTENT. THE MANUFACTURER WAS NOTIFIED, WHO STATED THE BUCKLE ASSEMBLY WOULD ONLY BE REPLACED IF THE PROBLEM COULD BE REPLICATED AT THE DEALERSHIP.

CONSUMER COMPLAINT CONCERNING THE POOR QUALITY OF GM AND GMAC PRODUCTS. *TS THE CONSUMER RECEIVED A RECALL NOTICE REGARDING THE FRONT BUCKLE ASSEMBLY ON HIS SEAT BELT. THE CONSUMER HAD ALREADY BEEN EXPERIENCING PROBLEMS PRIOR TO THE RECALL. *JB

AIR BAGS FAILED ON CRASH. *NM

OUR 2004 CHEVY EXPRESS VAN STALLED SERVERAL(12) TIMES WITHIN A 14 MILE DISTANCE ON THE INTERSTATE IN DENVER, CO. THE WIFE WAS ABLE TO GET IT HOME, AND WE CONTACTED THE LOCAL CHEVY DEALER (STEVENSON CHEVY, GOLDEN CO.) THE SERVICE ADVISOR ADVISED US THAT CHEVY IS HAVING A PROBLEM WITH FUEL PUMPS OVERHEATING AND IS WORKING THE PROBLEM. NO RECALL HAS BEEN ISSUED FOR THE FUEL PUMP PROBLEM FROM CHEVY. YES, THE FUEL PUMP WAS REPLACE AT SEVENSON CHEVY IN GOLDEN, CO ON 21 JULY. THIS IS OUR SECOND OCCURANCE OF A FUEL PUMP FAILURE IN A NEW CHEVY VEHICLE. OUR FIRST OCCURANCE WAS IN OUR NEW 2001 TAHOE, WHERE IT STRANDED US IN THE MIDDLE OF KANSAS, WHEN THE FUEL PUMP FAILED.

DT: THE VEHICLE IS A 2004 CHEVROLET EXPRESS 2500 VAN. ON 7-11-05 THE VEHICLE WAS MAKING INTERMITTENT KNOCKING NOISES. THE VEHICLE WAS STILL ABLE TO GO AT THIS POINT. THIS HAD BEEN GOING ON FOR A COUPLE OF DAYS. THE PROBLEM HAD BECAME WORSE, SO THE CONSUMER TOOK THE VEHICLE TO MIDAS. THE MECHANIC TOLD THE CONSUMER THAT THE FLY WHEEL HAD FAILED. THE CONSUMER HAD TO REPLACE THE WATER PUMP, BATTERY AND THE ALTERNATOR . *JB

THREE TIMES OUR VEHICLE ENGINE HAS ABRUPTLY STOPPED RUNNING IN CROWDED INTERSTATE TRAFFIC, ENDANGERING THE LIVES OF US AND OCCUPANTS OF ADJACENT VEHICLES. THE FIRST WAS AUGUST 7, 2004 ON INTERSTATE 40 NEAR KINGMAN AZ. OUR FIRST THOUGHT WAS THAT WE RAN OUT OF GAS, BUT THE GAUGE REGISTERED !/4 FULL AND WHEN WE ADDED GAS IT TOOK ONLY 22.8 GALLONS (31 GALLON TANK). THE SECOND WAS MAY 23, 2005 ON INTERSTATE 25 PASSING THROUGH COLORADO SPRINGS CO. THE GAS TANK WAS 3/4 FULL. FORTUNATELY, WE WERE ABLE TO COAST INTO THE RIGHT LANE AND OFF TO THE RIGHT SHOULDER WITHOUT CAUSING AN ACCIDENT. WE WERE TOWED TO TEAM CHEVROLET SERVICE DEPARTMENT (719-380-6020) IN COLORADO SPRINGS WHO FOUND "LEAN CODE", SUSPECTED FUEL PUMP PROBLEM, BUT VEHICLE SEEMED OK IN 2 ROAD TEST DRIVES. ON RETURN HOME TO ALBUQUERQUE, GALLES CHEVROLET SERVICE DEPARTMENT (505-766-6800) FOUND CODES P0174, P0171 AND P0300. THEY REPLACED FUEL PUMP MODULE (PART NUMBER 89060662, *MODULE 3.107) AT MILEAGE 8,826 (JUNE 9-16, 2005). THE THIRD TIME WAS ON JULY 1, 2005 ON INTERSTATE 40 APPROACHING WILLIAMS AZ IN THE MIDDLE OF HEAVY TRUCK TRAFFIC TRAVELING AT INTERSTATE SPEED LIMIT (75 MPH). WE WERE IN THE LEFT LANE ADJACENT TO GUARDRAIL WITH NO LEFT HIGHWAY SHOULDER AND WE NARROWLY ESCAPED CAUSING A MULTI-VEHICLE CRASH. THIS TIME WE WERE TOWED TO TYRRELL-MARXEN CHEVROLET SERVICE DEPARTMENT (928-774-5268) IN FLAGSTAFF AZ. THEY FOUND "CODES P0171 AND P0174 TRACED TO FAULTY FUEL MODULE". THEY REPLACED FUEL MODULE (PART NUMBER 88965421