2004 Chevrolet Express 3500 Service and Repair Manual

This factory service and repair manual for the 2004 Chevrolet Express 3500 splits its engine coverage three ways, between a 6.0L V8 of 364 cubic inches set up for gasoline or compressed natural gas, a 4.8L of 294 and a 5.3L of 325. Body choice remains five: three-door cargo and passenger vans in two lengths and the two-door cutaway. Two trims, Base and LS, define equipment. Because the same chassis underpins cargo and passenger versions alike, the chassis and brake material applies across the whole range.

Engines covered

• 6.0L V8 (364 cu in) — OHV, naturally aspirated, gasoline or CNG
• 4.8L V8 (294 cu in) — OHV, naturally aspirated, gasoline
• 5.3L V8 (325 cu in) — OHV, naturally aspirated, gasoline

Body styles covered

• 3-door extended cargo van
• 3-door standard cargo van
• 3-door extended passenger van
• 3-door standard passenger van
• 2-door cutaway van

Trims covered

• Base
• LS

Known issues on the 2004 Express 3500. Seven recalls are recorded. One concerns a hydraulic brake booster accumulator that can crack and separate, losing fluid and the assist that goes with it. Another concerns a transmission shift cable that can come apart, leaving lever position and indicator disagreeing so the van may move in a direction the driver did not choose. A third concerns front belt buckle latches made brittle enough to fail under crash loads. Of 57 complaints, fifteen name the service brakes and six each the fuel and propulsion system and the steering.