2004 Chevrolet Express: Reliability Data

Source: NHTSA — 26 complaints
26
Total Complaints
109,500mi
Median Mileage
SERVICE BRAKES
Top Issue
1
Crash Reports

When Do Complaints Happen?

Distribution of NHTSA complaints by vehicle mileage at time of report.

36,337 25th Percentile
109,500 Median Mileage
140,000 75th Percentile

What Fails?

Most reported component issues from NHTSA complaints.

SERVICE BRAKES
3
SERVICE BRAKES, HYDRAULIC
3
FUEL/PROPULSION SYSTEM
2
FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP
2
STRUCTURE:BODY
2
SEAT BELTS
2
STEERING:LINKAGES:KNUCKLE:SPINDLE:ARM
1
AIR BAGS
1
ENGINE AND ENGINE COOLING:ENGINE
1
ELECTRICAL SYSTEM:ALTERNATOR/GENERATOR/REGULATOR
1

Severity Assessment

1
Crashes
2
Fires
0
Injuries
0
Deaths

Sample Complaint Reports

"LEFT FRONT WHEEL DISENGAGED FROM VAN AT 55 MILES PER HOUR ON THE INTERSTATE DUE TO A NUT FALLING OFF OF THE SPINDLE. THIS WAS A VERY DANGEROUS AND COSTLY SITUATION."
"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 F..."
"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 ..."

Source: NHTSA ODI Complaints Database. Names and identifying details omitted.

Data source: View this vehicle on NHTSA.gov | NHTSA ODI Complaints Database. Public domain.

Methodology: Complaint counts and mileage distributions are computed directly from consumer-reported NHTSA complaints. This data represents reported issues, not failure rates — vehicles without complaints are not represented. Full methodology.

Data through: 2026-03-28