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


fairly significant
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
15,062 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 fuel system problems

fuel system problem

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2004 Chevrolet Express Owner Comments

problem #2

Jul 202005

Express 8-cyl

  • Automatic transmission
  • 19,250 miles


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.

- Lakewood, CO, USA

problem #1

Jul 012005

Express 8-cyl

  • Automatic transmission
  • 10,875 miles
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 module ki 3.107) at mileage 10875 (July 2, 2005). We like our roadtrek 170 popular (class B conversion van), but after these three (3) serious automotive system failures (plus wiper motor failure) we have serious concerns about safety of us & others when these things occur unexpectedly in heavy, high-speed interstate traffic.

- Albuquerque, NM, USA

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