2003 Chevrolet Express 3500 Problems

RepairPal has identified the most common problems with the 2003 Chevrolet Express 3500 as reported by actual vehicle owners. We'll tell you what the problem is and what it'll take to fix it.

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10
Known Problems

The tail light wiring harness in the cargo area is not protected very well. As a result it may become damaged due to normal wear a tear. This damage can causing some or all of the rear lights to stop working.

It is common for the fuel level sensor in the fuel tank read the fuel level incorrectly. The sensor must be replaced to correct the condition. Our technicians recommend having the complete fuel pump module replaced on high mileage vehicles.

A Loose or worn gas cap may cause Check Engine Light to illuminate.

The spark plugs should be replaced every 100,000 miles. Our technicians recommend replacing the spark plug wires also at this time.

One or both secondary air injection check valves may become restricted causing poor air flow resulting in illumination of the Check Engine Light. It is often recommend to replace both check valves even if a fault code is set for only one bank of cylinders. Replacing only one valve may result in a return trip to the repair shop.

Our technicians recommend flushing the brake fluid every 60,000 miles.  Brake fluid that is dirty may cause problems in the brake system.

Extended life coolant may become contaminated and require cooling system service before the recommended 100,000 miles.
Our technicians highly recommend that the transmission is serviced every 30,000 miles to avoid problems and maintain optimal operating order.

The fuel pump may fail causing the engine to stall and not restart. Our technicians recommend replacing the fuel filter every 30,000 miles to help prevent undue strain on the fuel pump.

Various electrical components under the front carpet/rubber mat may become damaged if excess water is used to clean the rear cargo area.