2004 Chevrolet Express 3500

Introduction:

The 2004 Chevrolet Express 3500 is a full-size passenger van offered with a variety of engine and transmission options. The standard engine is a 5.3L V8 producing 290 horsepower and 325 lb-ft of torque. A 6.0L V8 producing 300 horsepower and 360 lb-ft of torque, a 6.6L Duramax V8 turbodiesel producing 210 horsepower and 450 lb-ft of torque, and an 8.1L V8 producing 340 horsepower and 455 lb-ft of torque are also available. Transmission options include a 4-speed automatic, a 6-speed automatic, and a 5-speed manual. The Express 3500 is known for its spacious interior, powerful engines, and towing and hauling capabilities. However, like any vehicle, it has some common issues.

Engine

5.3L V8

• Intake Manifold Gasket Failure: The intake manifold gasket can fail, leading to coolant and oil leaks. Symptoms include a drop in coolant level, an increase in oil consumption, and a rough idle. Solution: Replace the intake manifold gasket. Estimated Cost to Fix: $500 - $1,000.
• Oil Pan Gasket Leak: The oil pan gasket can leak, causing oil to leak from the bottom of the engine. Symptoms include an oil leak and a low oil level. Solution: Replace the oil pan gasket. Estimated Cost to Fix: $200 - $400.

6.0L V8

• Vortec Active Fuel Management (AFM) Lifter Failure: The AFM lifters can fail, causing a loss of power, a rough idle, and a check engine light. Symptoms include a ticking noise from the engine, a rough idle, and a loss of power. Solution: Replace the AFM lifters. Estimated Cost to Fix: $2,000 - $3,000.

6.6L Duramax V8

• Turbocharger Failure: The turbocharger can fail, leading to a loss of power and a check engine light. Symptoms include a loss of power, a whistling noise from the engine, and a check engine light. Solution: Replace the turbocharger. Estimated Cost to Fix: $2,500 - $4,000.
• Injector Failure: The injectors can fail, causing a loss of power, a rough idle, and a check engine light. Symptoms include a loss of power, a rough idle, and a check engine light. Solution: Replace the injectors. Estimated Cost to Fix: $1,000 - $2,000.

8.1L V8

• Head Gasket Failure: The head gasket can fail, leading to a loss of coolant and a rough idle. Symptoms include a drop in coolant level, an increase in oil consumption, and a rough idle. Solution: Replace the head gasket. Estimated Cost to Fix: $1,500 - $2,500.

Transmission

4-Speed Automatic

• Transmission Slipping: The transmission may slip, causing a loss of power and a rough shift. Symptoms include a loss of power, a rough shift, and a check engine light. Solution: Rebuild or replace the transmission. Estimated Cost to Fix: $2,000 - $4,000.

6-Speed Automatic

• Torque Converter Failure: The torque converter can fail, leading to a loss of power and a rough shift. Symptoms include a loss of power, a rough shift, and a check engine light. Solution: Replace the torque converter. Estimated Cost to Fix: $1,000 - $2,000.

5-Speed Manual

• Clutch Failure: The clutch can fail, leading to a loss of power and a difficulty shifting gears. Symptoms include a loss of power, a difficulty shifting gears, and a burning smell. Solution: Replace the clutch. Estimated Cost to Fix: $500 - $1,000.

Suspension

• Front Suspension Lower Control Arm Bushing Failure: The front suspension lower control arm bushings can fail, causing a clunking noise and a rough ride. Symptoms include a clunking noise from the front suspension and a rough ride. Solution: Replace the lower control arm bushings. Estimated Cost to Fix: $400 - $800.
• Rear Suspension Leaf Spring Failure: The rear suspension leaf springs can fail, causing the rear of the vehicle to sag and a rough ride. Symptoms include the rear of the vehicle sagging and a rough ride. Solution: Replace the leaf springs. Estimated Cost to Fix: $500 - $1,000.

Electrical

• Alternator Failure: The alternator can fail, leading to a loss of electrical power and a dead battery. Symptoms include a loss of electrical power, a dead battery, and a check engine light. Solution: Replace the alternator. Estimated Cost to Fix: $500 - $1,000.
• Battery Failure: The battery can fail, leading to a loss of electrical power and a dead battery. Symptoms include a loss of electrical power, a dead battery, and a check engine light. Solution: Replace the battery. Estimated Cost to Fix: $100 - $200.

Exterior

• Front Bumper Cover Cracking: The front bumper cover can crack, leading to a cosmetic defect. Symptoms include a cracked front bumper cover. Solution: Replace the front bumper cover. Estimated Cost to Fix: $500 - $1,000.

Interior

• Power Window Failure: The power windows can fail, leading to a window that cannot be opened or closed. Symptoms include a window that cannot be opened or closed. Solution: Replace the power window motor or switch. Estimated Cost to Fix: $200 - $400.
• Door Lock Failure: The door locks can fail, leading to a door that cannot be opened or closed. Symptoms include a door that cannot be opened or closed. Solution: Replace the door lock actuator. Estimated Cost to Fix: $200 - $400.

Summary

The 2004 Chevrolet Express 3500 is a reliable and capable van, but it is not without its issues. The most severe issues are related to the engine and transmission, and can be expensive to fix. However, many of the other issues are relatively minor and can be fixed for a reasonable cost. Overall, the Express 3500 is a good choice for those who need a spacious and powerful van, but it is important to be aware of the potential issues before buying.