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Resources for the Repair and Maintenance of your Chevrolet Express 2500

Chevrolet Express 2500 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 2500 Problems

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.

Miscellaneous -- Verified

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

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 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.

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 2500 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 2500 Questions and Answers

ali777, 1997 Chevrolet Express 2500, 5.0L V8, East Elmhurst, NY

how to reprogram engine control module that is called VCM

packman76, 1998 Chevrolet Express 2500, 5.0L V8, Akron, IN

Where is the low side AC service port on a 1998 Chevy Express? Do I add the R134 with the engine on or off?

jcarson1, 1997 Chevrolet Express 2500, 5.0L V8, Crystal Lake, IL

The heat was only working on the highest speed for a while now. It stopped working completely and the fuse is good.

Visitor, 1997 Chevrolet Express 2500, 5.7L V8, Brandon, FL

how to replace rear main oil seal. leakin bad between eng and trans

gcat61, 1997 Chevrolet Express 2500, 5.0L V8, Butner, NC

dont know how to find short any suggestions? Found P.E.D. fuse link with open eyelet not connected to anything.

Write a Review About Your Car

Chevrolet Express 2500 Reviews

have 115000 miles not one problem

GREAT PASSENGER VAN WITH OVER 100K. HAVE HAD TO REPLACE WATER PUMP TWICE. NOT SO CHEAP. ELECTRICAL WIRING SYSTEM POORLY DESIGNED ACCESS. INTERIOR LIGHT SWITCH PROBLEM ALONG WITH REAR BACK-UP LIGHT FAILURE. I REALLY LIKE THIS VAN. WITH ITS SMALL PROBLEMS.

I have had several Express vans over the years. This one and the others all had problems with the rear a/c lines leaking due to the way they are mounted. The other main problem is the side door hinges seize up due to rust, and yes I kept them lubricated. Both of these problems have been occurring for several years and are expensive repairs if completed at a dealer. These design problems should have been addressed by GM years ago.

I have the Diesel version and get almost 20 mpg empty on the highway and 16 mpg highway when towing our 7000# work trailer. The vent control on the heating system would not change from vent to defrost. The dealer said it was the vacuum pump which was repaired but is now making strange noises. Of course it started at 36,000 miles right after the bumper to bumper warranty expired. Only other issue was a squeaky alternator belt fixed under warranty.