The 2004 GMC Savana has 7 NHTSA recall campaigns affecting an estimated 734,221 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 17 complaints with NHTSA, most often about the service brakes, hydraulic. Last updated July 5, 2026.
General Motors, LLC (GM) is recalling certain 2003-2023 Chevrolet Express Cutaway and GMC Savana Cutaway incomplete vehicles equipped with wiring for an optional rear heating, ventilation, and air-conditioning (HVAC) system. When the HVAC blower motor circuit is left unused with exposed connectors and wiring, the…
Consequence
An overheated electrical circuit increases the risk of a fire.
Remedy
Dealers will properly seal the rear HVAC blower motor circuits at the left side B-pillar, free of charge. Owner notification letters were mailed May 2, 2023. Owners may contact Chevrolet customer service at 1-800-222-1020 or GMC customer service at 1-800-462-8782. GMC's number for this recall is N222386050.
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,…
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.
SEAT BELTS05V5580002005-12-19425,593 affected
Defect
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…
SERVICE BRAKES, HYDRAULIC05V0430002005-02-0877,411 affected
Defect
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…
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…
POWER TRAIN04V3200002004-07-061,792 affected
Defect
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.
SEAT BELTS04V1890002004-04-19331 affected
Defect
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.
SERVICE BRAKES, HYDRAULIC04V0450002004-02-0468,875 affected
Defect
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.
Complaints by component
SERVICE BRAKES, HYDRAULIC
2
AIR BAGS:FRONTAL
1
1crashes1injuries
ENGINE AND ENGINE COOLING
1
EXTERIOR LIGHTING:TAIL LIGHTS
1
1fires
FUEL SYSTEM, GASOLINE
1
FUEL SYSTEM, GASOLINE:DELIVERY
1
FUEL/PROPULSION SYSTEM
1
POWER TRAIN
1
POWER TRAIN:AUTOMATIC TRANSMISSION
1
1fires
SEAT BELTS:REAR/OTHER
1
Total complaints17
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information removed.
“The contact owns a 2004 gmc savana. The contact stated that while driving at an undisclosed speed, the brake pedal went to the floorboard while depressed. The dealer was made aware of the failure and scheduled an upcoming appointment; however, the vehicle was not diagnosed nor repaired. The…”
“Problem is with a new tire purchase bf goodrich lt245/75r16 bfg commercial ta a/s2. I notice flat spotting every morning and it could take 1/2 hr of driving to clear up been driving for over 60 yrs and have never experienced this before. I consider this to be a bad tire. If it has flat spots with…”
“The vehicle is out of warranty. However, it only has 63k plus miles on the odometer. The transmission suddenly became erratic. It would not shift to "d", but the second and the first gear works fine. We were told by gmc customer service to have it inspected and have it diagnosed by a gmc dealer to…”
“No incident ...yet. Noticed the smell of gas after refueling just before christmas 2012. It has been getting worse ever since. Checked out recalls and saw this one, but never received a recall notice. Called local dealer and told me that it was not covered. Something is wrong here. This recall…”
“No incident ...yet. Noticed the smell of gas after refueling just before christmas 2012. It has been getting worse ever since. Checked out recalls and saw this one, but never received a recall notice. Called local dealer and told me that it was not covered. Something is wrong here. This recall…”
“Submission from explorer van co., re receipt of your correspondence dated july 10, 2014 regarding the early warning reporting of deaths and injuries. *smd the driver was involved in an accident, while driving a 2004 gmc savana, which resulted in serious and permanent injuries. *jb”
“Tl*the contact owns a 2004 gmc savana. While driving less than 20 mph and approaching a stop sign, the brake pedal extended to the floor. The contact had to use maximum effort in order for the brakes to catch. His vin was not included in nhtsa campaign id number 05v043000. The failure and current…”
“Fuel line from gas tank to "quick connect" split near the muffler. With the pressure of the fuel pump, gasoline was spewing out of the line under the truck near the muffler. It had happened two weeks or so earlier but I didn't notice it because I'd had a gas spill from a leaf blower in the back of…”
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL,
FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 2004 GMC Savana as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
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