2004 Chevrolet Express 3500 15 Passenger recalls & complaints

Component: FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP
Summary: 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.
Consequence: 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.
Notes: GM's campaign number is 12166. Owners may also contact the National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153), or go to www.safercar.gov.

Component: EXTERIOR LIGHTING
Summary: 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.
Consequence: 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.
Notes: THIS RECALL ONLY PERTAINS TO AFTERMARKET REPLACEMENT EQUIPMENT AND HAS NO RELATION TO ANY ORIGINAL EQUIPMENT INSTALLED ON VEHICLES PRODUCED BY THE VEHICLE MANUFACTURER. IN ORDER TO DETERMINE IF YOUR AFTERMARKET LAMP ASSEMBLY IS AFFECTED BY THIS NONCOMPLIANCE, PLEASE REVIEW THE LIST OF MODEL NUMBERS PROVIDED TO US BY SABERSPORT. THE LIST CAN BE FOUND UNDER "DOCUMENT SEARCH" LOCATED AT THE BOTTOM OF YOUR SCREEN. OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO <A HREF=HTTP://WWW.SAFERCAR.GOV>HTTP://WWW.SAFERCAR.GOV</A> .

Component: SEAT BELTS
Summary: ON CERTAIN FULL-SIZE PASSENGER, CARGO, OR CUTAWAY VANS, THE FRONT AND REAR SEAT BELT BUCKLES WILL NOT LATCH OR WILL NOT UNLATCH.
Consequence: 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.
Notes: GM RECALL NO. 05113. CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

Component: SERVICE BRAKES, HYDRAULIC
Summary: 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.
Consequence: 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.
Notes: GM RECALL NO. 05006. CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

Component: SEAT BELTS:FRONT:BUCKLE ASSEMBLY
Summary: 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.
Consequence: 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.
Notes: GM RECALL NO. 04025. CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

Component: POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:COLUMN SHIFT
Summary: 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.
Consequence: 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.
Notes: GM RECALL NO. 04061. CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

Component: SERVICE BRAKES, HYDRAULIC
Summary: 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.
Consequence: 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.
Notes: GM RECALL NO. 04004. CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

03/01/2022 · Fuel system
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.

12/30/2021 · Suspension
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…

11/09/2016 · Fuel system
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

10/17/2016 · Visibility (wipers / glass)
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 0…

09/08/2016 · Body / structure · fire
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.

08/09/2016 · Seat belts
TWO REAR BUCKET SEAT BELT CABLES HAVE BROKEN WITHOUT IMPACT.

04/11/2016 · Brakes
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 THE METAL BRAKE LINE CAUSING THE FAILURE. FAILURE MILEAGE 43…

09/04/2015 · Wheels / tires
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 CRACKS AND NEEDED TO BE REPLACED. IN ADDITION, MULTIPLE PARTS NE…