The 2004 Chevrolet Express 2500 has 1 NHTSA recall campaign affecting an estimated 2 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 10 complaints with NHTSA, most often about the engine and engine cooling. Last updated July 5, 2026.
Recall campaigns
EXTERIOR LIGHTING05V5590002005-12-132 affected
Defect
CERTAIN CONVERSION VANS BUILT ON GMC/CHEVROLET CHASSIS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES AND ASSOCIATED EQUIPMENT." THE HOUSING LENS OF THE CENTER HIGH MOUNTED STOP LAMP DOES NOT ALLOW ENOUGH LIGHT TO EMIT FROM THE LAMP.
Consequence
FOLLOWING VEHICLES MAY NOT BE FULLY INFORMED OF VEHICLE BRAKING. REAR-END CRASHES AND INJURY TO OCCUPANTS MAY OCCUR.
Remedy
QUALITY COACHES IS WORKING WITH AUDIOVOX TO REPLACE THE CENTER HIGH-MOUNTED BRAKE LAMP ASSEMBLY. OWNERS MAY CONTACT QUALITY COACHES AT 1-800-373-6357 OR ASA AT 1-800-274-1886.
Complaints by component
ENGINE AND ENGINE COOLING
2
POWER TRAIN
2
ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL
1
EQUIPMENT
1
POWER TRAIN:AUTOMATIC TRANSMISSION
1
SERVICE BRAKES
1
SERVICE BRAKES, HYDRAULIC
1
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP
1
1crashes
Total complaints10
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information removed.
“Tl* the contact owns a 2004 chevrolet express 2500. The contact stated that when the brakes were applied, the vehicle shook violently. The vehicle was taken to an independent mechanic where the brake pads and rotors were replaced; however, the failure continued. The contact had to apply extreme…”
“Tl* the contact owns a 2004 chevrolet express 2500. The contact stated whenever at an idle a loud metal to metal noise would emit continuously. The vehicle was taken to an independent mechanic on two separate occasions where the cracked flywheel was replaced each time. The manufacturer was not…”
“As I attempted to speed up in traffic, I heard a noise and the vehicle suddenly slowed down. I was able to get it off the highway on to a side road. Once there, it would not start. On closer inspection, I saw that the belt had come apart and off the pulley's. I had the van towed to my home and…”
“Mysterious coolant leak. Reservoir is low and needs refilling often. Mechanic has performed pressure test to no avail. No coolant on ground at any point. No visible signs of leak. This began right after 2nd cracked flywheel was replaced. At the same time a lifter knock began as well. 1st flywheel…”
“Mysterious coolant leak. Reservoir is low and needs refilling often. Mechanic has performed pressure test to no avail. No coolant on ground at any point. No visible signs of leak. This began right after 2nd cracked flywheel was replaced. At the same time a lifter knock began as well. 1st flywheel…”
“Repeated cracked flywheel. Original cracked just over 100k miles. Replacement now cracked 40k miles later. *tr”
“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…”
“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…”
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL,
FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 2004 Chevrolet Express 2500 as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
contains ads and affiliate links. Full methodology.