Chevrolet Express 2500 Repair and Maintenance

A guide to problems, costs, maintenance and repair for your Chevrolet Express 2500

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.

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.

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

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2004 Express van 4.8l with 140k miles.

Past couple years:
Hard to start after fuel fill up.
Random miss and hesitation when accelerating. Pumping throttle would cure. Then randomly again from 30 min to 7 days between.

Lately:
Missing most of the time, especially when hot. Rough idle and...

I'm trying to get the monitors set.

we have had water dip out the rear doors as well. Our son is handicapped and the floor he parks his wheel chair on also has warped the plywood. Any ideas? Thanks

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The chassis electrical module can short due to internal contamination. This can result in the vehicle stalling. Dealers will replace the chassis electronic module free of charge to resolve the concern.

Certain vehicles equipped to run on compressed natural gas are being recalled because the high pressure natural gas regulator could develop a leak, increasing the risk of a fire or explosion. Dealers will replace the natural gas regulator to correct this concern.

Certain vehicles are being recalled because if a crash were to occur not requiring deployment of the front airbags, the head of an unbelted front seat passenger could hit the instrument panel, resulting in personal injury because the panel may not sufficiently absorb the impact. As of this writing, General Motors is still working on a remedy for this concern.

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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 sho...

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 ...

have 115000 miles not one problem

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