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Resources for the Repair and Maintenance of your Chevrolet Express 1500

Chevrolet Express 1500 Models:

Image for car images Chevrolet 1996 1998 Chevrolet G Van size thumb Image for car images Chevrolet 1999 2002 Chevrolet Express size thumb Image for car images Chevrolet 2003 2011 Chevrolet Express size thumb

Chevrolet Express 1500 Problems

Engine -- Verified

The intake manifold gasket may develop and external engine oil or coolant leak. In some cases, an internal coolant leak may occur causing coolant to mix with the engine oil. Running the engine with a coolant/oil mix may result in engine damage. Replacing the intake manifold gasket should correct this issue.

Electrical & Lights -- Verified

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.

Engine -- Verified

One or more fuel injectors may become stuck closed causing an engine misfire and the Check Engine Light to illuminate. Our technicians tell us that this problem can be caused by some fuel additives. There are special procedures which may be able to restore the affected injector. If this fails the affected injector must be replaced.

Electrical & Lights -- Verified

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.

Engine -- Verified

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.

Chevrolet Express 1500 Recalls (Recent)

Body, Interior & Misc., March 31, 2006

RepairPal Expert Overview:

The tire and loading information label on the driver's side door frame may be inaccurate. A misprinted label could lead to overloading of the vehicle, which could possibly lead to tire failure and a crash. Owners will be provided with corrected labels and installation instructions. At customers' request, a dealer can install the label for them. The recall began March 31, 2006. The GM recall number is 05109.

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Body, Interior & Misc., August 20, 2003

RepairPal Expert Overview:

The owner's manual does not explain the child restraint anchor location symbols for the lower universal anchorage system. This does not meet the Federal Motor Vehicle Safety Standard. Owners were sent supplements to the owner's manual explaining the location symbols in the vehicle. The recall began August 18, 2003. The GM recall number is 03039.

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Brakes, June 18, 2004

RepairPal Expert Overview:

The hydro-boost housing relief valve bore may be out of specification. The seal may fracture as a result, which may reduce braking assist and slightly increase the steering effort while braking. Under certain conditions, more braking effort will be required to stop the vehicle. Dealers will replace the hydro-boost relief valve. The recall began June 18, 2004. The GM recall number is 04004.

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Brakes, March 23, 2005

RepairPal Expert Overview:

On vehicles equipped with the Bosch hydraulic brake booster, the boost pressure accumulator may crack and break away from the hydro-boost assembly during normal operation. If this were to happen while the hood is open, fragments from the accumulator could injure people standing in the immediate area. The loss of fluid while driving would cause increased steering and braking effort and a crash could occur without warning. Dealers will test the hydro-boost assembly for function of the two-function valve. If the hydro-boost assembly fails the test, it will be replaced free of charge. The recall began March 23, 2005. The GM recall number is 05006.

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Suspension & Steering, October 14, 2005

RepairPal Expert Overview:

Some vehicles have a power steering hose that was not made to specification and may rupture under extreme steering conditions. If this were to happen, power steering assist would be lost and steering effort would increase. On vehicles equipped with hydro-boost brakes, braking effort would also increase. If power steering fluid were to spray on hot engine parts, an engine compartment fire could also occur. Dealers will inspect the power steering hose(s) for the two suspect date codes and replace them if needed. The recall began October 14, 2005. The GM recall number is 05086.

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Chevrolet Express 1500 Questions and Answers

Thinker, 1996 Chevrolet Express 1500, 5.7L V8, Lorton, VA

I have an intermitten problem of the fuel pressure dropping off and want to change the relay first to see if this fixes the problem. Where is it located on the 1996 Express 1500 van.

Visitor, 1996 Chevrolet Express 1500, 5.7L V8, Elyria, OH

recently the van has experienced a total loss of power when accelerating. diagnostic codes p1133 and p1153 and p0151 were found. i replaced both upstream o2 sensors and the maf sensor. no good. ...

johnbarth, 1996 Chevrolet Express 1500, Naperville, IL

I have a 96 chevy express. yesterday while idleing, it stalled and would not start. a few minutes later it would start it ran for about 2 miles then puttered out. would not start again, waited a fe...

kraezone, 1996 Chevrolet Express 1500, 5.7L V8, Cicero, IL

The van jumps whenever I shift it into gear but runs good after that so I don't think its the transmission or I'm not sure if its the timing that's off.

Visitor, 1996 Chevrolet Express 1500, Denver, CO

wind blew door open and it wouldn't close properly. Macco repaired for $150. Two weeks later door wouldn't lock shut. They want an additional $500 to repair. Said they did the quick f...

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Chevrolet Express 1500 Reviews

I went to have my van smog check but it failed due to bad O2 sensor Bank 1 sensor 3. replaced a new sensor but still having a note that read on the gauge panel: Service engine soon. What is your suggestion in order for the van to pass the smog check. Your recommendation is highly appreciated.

Purchased the van new. Performed perfectly the 1st year. During the 2nd year at 30k had to replace the front headlights and rear turn signals. At 35k the left rear wheel sensor for the ABS system went out and was replaced. At 51k the Fuel Pump stopped working and was replaced.

I have a beautiful 1999 Chevy Express Conversion Van by Starcraft. The only problem here lately is I have trouble starting it sometimes in damp weather but once cranked it will start all day. My service light never came on.But it just came on and I had it checked out and the code says it is my o2 sensorand I am wondering if that has anything to do with the cranking of it

i have over 500,000 on my 2004 chevrolet express and i am in desperate need of a drivers seat as this one is down to the springs. i love my van and hope to take it to a million!i take good care of it.

I own a 1998 chevrolet Express, I don't know if it's a 1500 or 2500 it's a v8, but I don't know if it's a 5.0L or a 5.7L

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