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Chevrolet Express 2500 Repair and Maintenance

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

Chevrolet Express 2500 Problems

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.

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

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.

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Chevrolet Express 2500 Recalls

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.

IMPCO Technologies installed a compressed natural gas (CNG) fuel system as original equipment on certain 2011-2013 full size GM vans. These vans are being recalled because the electrical connector on the fuel shut off solenoid can corrode, causing the connector to overheat, increasing the risk of a fire. Both dealers and fleet operators will be performing the necessary updates to correct this concern. The corrections include: replacing the fuel shut off solenoid, fuel pump fuse, and adjusting the wiring routing.

Chevrolet Express and GMC Savana vans are used by the Explorer Van Company as the base vehicle for some of their van conversions. Certain Explorer vans are being recalled because the wiring under the power seats may not have been properly secured during vehicle conversion. The wires can be damaged by the seat mechanism resulting in an electrical short and possibly a fire. Dealers will inspect and replace any seat wire harness found to be damaged. If the harness is not damaged, it will be secured to prevent future damage.

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Chevrolet Express 2500 Reviews

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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