Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety.

Print this page Notes: The Chevy Express is mechanically identical to the GMC Savana.


definitely annoying
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
41,830 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2004 Chevrolet Express brakes problems

brakes problem

Find something helpful? Spread the word.
Get notified about new defects, investigations, recalls & lawsuits for the 2004 Chevrolet Express:

Unsubscribe any time. We don't sell/share your email.

2004 Chevrolet Express Owner Comments

problem #8

Oct 252009


  • 65,000 miles


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.

- New Bloomfield, PA, USA

problem #7

Nov 052007


  • 18,580 miles
2004 Chevy Express 1500.

- Toledo, OH, USA

problem #6

Jan 092010


  • 26,500 miles
I own a 2004 Silverado 2500 hd with 26,500 miles on it. I had my truck serviced for speedometer that was not working and was told by karl Chevy here in ankeny, ia that all of my rotors and brake pads needed to be replaced because of rust. GM ought to fix my brakes for free, they need to recall. I am 61 and have owned a few automobiles and have never had to replace rotors with such low mileage. The majority of miles are highway. I have been in a rideshare pool using a metro van provided to our pool for the last four years as the main driver.

- Des Moines, IA, USA

problem #5

Aug 162009


  • 66,445 miles


The contact owns a 2004 Chevrolet cargo express van 3500. While driving 45 mph he had attempted to brake and noticed that the brake pedal extended to the floor and the vehicle could only be stopped by manually down shifting the gears. The dealer informed the contact that the coolant line rubbed through to the brake line. There was a burning smell prior to the failure in the front axle area of the vehicle. The current and failure mileages were 66445.

- Waterford, MI, USA

problem #4

Jun 212009


  • 50,000 miles
The brakes on my 2004 Chevy Express 3500 activate without warning, stopping the vehicle in traffic. A warning light indicated a failure of the stability control system. Fault code C0196 was recorded. My dealer replaced the electronic brake control module, but the problem continues to occur. I was almost rear-ended when the vehicle stopped without warning in traffic.

- Homer City, PA, USA

problem #3

Mar 282009


  • 35,000 miles
ABS engages at slow speed, at tail end of braking, even on dry surfaces. This has been going on for at least eight months. Started sometime in early summer/late spring 2008.

- Beverly Hills, MI, USA

problem #2

Jun 202008


  • 36,117 miles
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.

- Penfield, NY, USA

problem #1

Oct 152008


  • 37,000 miles
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.

- Penfield, NY, USA

Not what you are looking for?