2002 Chevrolet Express

Routine

Owners filed 56 complaints about this vehicle with federal regulators, most often about the body and frame. No safety recall has been issued.

Not among the Chevrolet Express years to avoid. Which Chevrolet Express years to avoid →

When it fails
020k40k60k90k120k200k
34,000 milesMedian miles at failure

42 complaints record an odometer reading. Failures cluster around 10,000–20,000 miles.

Most common 2002 Chevrolet Express problems

8 of the 56 complaints (14%) are about the body and frame.

ComponentReportsCrashesFiresInjuries
Tires › Tread/Belt2
000
Tires › Sidewall2
000
Suspension2
000
Structure › Frame and Members · body and frame2
000
Structure › Body › Door · body and frame2
000
Structure › Body · body and frame2
000
Steering › Gear Box (other Than Rack and Pinion)2
000
Service Brakes, Hydraulic › Foundation Components › Disc · brakes2
000
Fuel System, Gasoline › Fuel Injection System · fuel system2
000
Exterior Lighting › Brake Lights · headlights2
000

What owners reported

Newest filings
Electrical System › Instrument Panel › Speedometer/Odometer
Filed Oct 19, 2026298,000 milesTX

Odometer Fraud. The contact purchased a 2002 Chevrolet Express. It was discovered that there was a mileage discrepancy. The vehicle was a private sale. At the time of purchase, the mileage was 180,000. It was later discovered through a diagnostic test that the mileage was 298,000. The seller was contacted and informed the contact that the instrument cluster was potentially tampered with by a previous seller. The seller denied a refund request due to an as-is sale and directed the contact to the NHTSA Hotline.

Suspension
Filed Sep 30, 2021100,000 milesSD

The contact owns a 2002 Chevrolet Express. The contact stated while driving 65 MPH, she heard an abnormal loud banging sound coming from the rear end of the vehicle. The contact stated that the passenger’s side rear axle detached from the vehicle, causing the tire to detach and roll away. The contact did not sustain any injury. The vehicle was towed to a tow lot. The dealer and the manufacturer were not notified. The vehicle was not diagnosed nor repaired. The approximate failure mileage was 100,000.

Structure › Body
Filed Aug 5, 201862,000 milesOH

THE SIDE HINGES SEIZE UP AND BREAK. IT THROWS THE DOOR ALIGNMENT OFF AND I AM NO LONGER ABLE TO COMPLETELY CLOSE THE FRONT SIDE DOOR AND IT KEEPS THE PASSENGER DOOR FROM OPENING ALSO. THIS IS A CONTINUEING PROBLEM CHEVROLET HAS WITH THEIR EXPRESS VANS. IT IS A DESIGN PROBLEM AND ALSO CHEAP MATERIALS CAUSED IT TO RUST AND SEIZE UP AND THEN BREAK THE HINGE, THE HINGE IS WELDED ON. VERY EXPENSIVE TO HAVE REPARED. IT IS DANGEROUS AS PEOPLE CAN NOT GET OUT OF THE VAN. CHEVROLET NEEDS TO OFFER AN INEXPENSIVE FIX FOR THIS.

Structure › Body
Filed Aug 8, 2015130,000 milesMI

WHEN I CAME OUTSIDE THE GLASS WAS BROKEN AND HAD BEEN THROWN TO THE OUTSIDE OF THE VEHICLE. THE VEHICLE HAD BEEN DRIVEN THE DAY BEFORE AND WAS FINE. IT WAS PARKED IN THE SHADE AND AWAY FROM ANYTHING WHICH COULD HAVE HIT IT. IT WAS LOCKED AND NOT TOUCHED IN ANY WAY. THE BROKEN FRAGMENTS WERE ON THE GROUND BELOW THE GLASS FRAME AREA. IT IS THE SAME TYPE OF GLASS THAT I SAW IN THE STORY ON THE NEWS YESTERDAY ABOUT THE SUN ROOFS THAT BREAK. WHEN I SAW THE STORY I KNEW THIS HAD TO BE THE EXPLANATION. I HAVE A PICTURE AND THE TEXT I SENT THAT DAY BECAUSE I WAS SO SHOCKED AT HOW SOMETHING LIKE THIS COULD HAPPEN, IT MADE NO SENSE. NOW IT MAKES PERFECT SENSE.

Unknown or Other
Filed Aug 30, 2013125,000 milesOH

PASSLOCK SECURITY SYSTEM CONSTANTLY WON'T ALLOW VAN TO START. CHEVROLET SAYS TO HAVE THE SYSTEM "RELEARN THE KEY" BY WAITING FOR 10 MIN THEN TRYING TO START THE VEHICLE. IT SOMETIMES TAKES 3-4 TRIES OF DOING THIS BEFORE IT STARTS.

Service Brakes, Hydraulic
Filed Feb 23, 2010108,000 milesDE

2002 CHEVY 2500 EXPRESS VAN. FAILURE OF POWER BOOSTER, LOST BOTH BRAKE POWER AS WELL AS STEERING POWER. ALMOST IMPOSSIBLE TO CONTROL CAR. REPLACED ONCE, FAILED AGAIN 6 MONTHS LATER. REPLACED AGAIN. FAILED AGAIN THIS YEAR. I AM NOW ON MY FORTH POWER BOOSTER, FAILURE IS VERY DANGEROUS AS YOU LOSE BOTH STEERING AND BRAKES AT SAME TIME. *TR

Visibility › Rearview Mirrors/Devices
Filed Apr 18, 200917,000 milesFL

DRIVER'S SIDE REAR VIEW MIRROR VIBRATES EXCESSIVELY. HARD TO VIEW ITEMS ON THE MIRROR. *TR

Engine and Engine Cooling
Filed Oct 3, 200716,594 milesPA

TL*THE CONTACT OWNS A 2002 CHEVROLET EXPRESS. WHILE DRIVING 50 MPH, THE VEHICLE COMPLETELY SHUT OFF AND WOULD NOT RESTART. THE VEHICLE WAS TOWED TO THE DEALER AND THEY REPLACED THE FUEL FILTER, HOWEVER, THE FAILURE RECURRED. THE VEHICLE WAS THEN TOWED TO A GM DEALER, WHO REPLACED THE CRANK SENSOR. THE CONTACT STATED THAT THE VEHICLE IS CURRENTLY OPERATING NORMALLY. THE CURRENT MILEAGE WAS 16,612 AND FAILURE MILEAGE WAS 16,594.

Engine and Engine Cooling › Engine
Filed Aug 23, 200769,700 milesNY

INTAKE MANIFOLD GASKET FAILURE CAUSING ENGINE TO SEIZE AT 69,700 MILES. *TR

Structure › Body › Door › Hinge and Attachments
Filed Jun 11, 200734,820 milesWI

ONE OF THE HINGES TO THE DOUBLE SIDE DOORS ON THE FULL SIZE 2002 CHEVROLET EXPRESS BROKE OFF TODAY. *AK

Service Brakes, Hydraulic › Foundation Components › Disc › Rotor
Filed Jan 15, 2007PA

BRAKES ON MY 2002 CHEVY EXPRESS VAN ARE NOT LARGE ENOUGH TO STOP VEHICLE WITHOUT WARPING ROTORS. THIS IN TURN CAUSES LONGER STOPPING DISTANCES AND A VIBRATION THAT CAUSES STEERING WHEEL TO PULSATE. *NM

Exterior Lighting › Brake Lights
Filed Nov 11, 200678,000 milesNJ

REAR BRAKE LIGHTS DOES NOT LIGHT AT THE SAME TIME. THEY OPERATE LIKE A CAROUSEL. WHEN THE LIGHT SWITCH IS TURNED ON ONLY THE CENTER BRAKE LIGHT ILLUMINATES. *JB

Power Train › Driveline › Driveshaft
Filed May 9, 200656,500 milesOK

THE REAR END WENT OUT AND THE ROTORS ARE WARPED. I HAD THE REAR END REPLACED AND THE SERVICE TECH SAID HE HAD NEVER SEEN ANYTHING LIKE THIS IN HIS HISTORY OF WORKING ON VEHICLES. I HAD JUST PURCHASED THE VAN JAN. 28TH AND IT HAD A 60 DAY WARRANTY. I HAD TAKEN IT BACK TO THE DEALERSHIP ON FEB 17TH AND REPORT THE NOISES IT WAS MAKING AND THEY IN TURN SAID NOTHING WAS WRONG. THE SERVICE TECH THAT REPLACED THE REAR END SAID IT COULD NOT HAVE BEEN MISSED BECAUSE THE DIFFERENTIAL WAS BENT COMPLETELY UP ON THE AXLES. HE SAID IT WAS DUE TO EITHER WHOEVER OWNED IT PREVIOUS HAD TOWED SOMETHING TO HEAVY OR THE THERE WAS A MANUFACTURER DEFECT IN THE DIFFERENTIAL. REGARDLESS HE DEALERSHIP (LAWRENCE MARSHALL) IN DENISON TX WILL NOT STAND BEHIND IT AND I AM OUT OF POCKET FOR THIS BIG EXPENSE. THEY OVER CHARGED ME FOR THE VEHICLE AND NOW THIS. I HAVE A BIG CONCERN BECAUSE THE NOISE IT WAS MAKING HAD STOPPED AFTER THE REAR END WAS REPLACED, BUT WHEN I WAS DRIVING IT TODAY IT CLUNKED TWO DIFFERENT TIMES, SAME NOISE AS BEFORE, SO NOW I AM WORRIED. I DON'T KNOW WHO TO TRUST TO HELP ME AS I HAVE BEEN RIPPED OFF SO BAD NOW. CAN YOU PLEASE HELP ME OR ADVISE ME WHERE I CAN HAVE THIS VEHICLE COMPLETELY CHECKED OUT. THE SERVICE TECH SAID IT WAS A MIRACLE THAT THE DRIVE SHAFT DID NOT FALL OUT ON THE TRIP MYSELF AND GRANDCHILDREN WERE ON. IT BROKE DOWN IN OHIO AND I LIVE IN OKLAHOMA SO OF COURSE IT SET ME BACK A LOT OF EXPENSE I COULD NOT AFFORD. I THOUGHT THE DEALERSHIP SHOULD STAND BEHIND THE 60 DAY W

Service Brakes, Hydraulic › Foundation Components › Hoses, Lines/Piping, and Fittings
Filed Apr 12, 200665,000 milesMI

DT*: THE CONTACT STATED WHILE APPLYING BRAKE PRESSURE AT VARIOUS SPEEDS, THERE WAS A THUMPING NOISE FROM THE UNDERHOOD AREA FOLLOWED BY ABS ACTIVATION. THE CONTACT INSPECTED UNDERNEATH THE VEHICLE AND DETERMINED BRAKE FLUID WAS LEAKING FROM A BRAKE LINE. THE VEHICLE IS SCHEDULED FOR FURTHER INSPECTION AT THE DEALER.

Visibility › Power Window Devices and Controls
Filed Apr 4, 200647,000 milesVA

2002 CHEVROLET CONVERSION VAN EXPRESS 1500 HAD A PROBLEM WITH THE DRIVERS SIDE WINDOW. EXPRESS WINDOW WOULD GO DOWN BUT NOT GO BACK UP. *TS THE MOTOR WAS REPLACED THREE TIMES, FINALLY THE SWITCH WAS REPLACED. THE BRAKES AND MASTER CYLINDER HAD TO BE REPLACED. THE CONSUMER WAS TOLD THE BRAKES WERE INSUFFICIENT FOR THE WEIGHT OF THE VEHICLE. THE MICHELIN TIRES ONLY LASTED 24,000 MILES. *JB

Service Brakes, Hydraulic › Foundation Components › Disc
Filed Mar 25, 200632,000 milesMA

BRAKES WERE MAKING A "GRUMBLING NOISE". NOT THE TYPICAL SQUEAL OR GRINDING NOISE ASSOCIATED WITH BRAKES. WENT TO THE DEALER AND HE SAID THE FRONT DISC BRAKES WERE BADLY WORN. ONLY 32,000 MILES ON THE VEHICLE. NEVER, NEVER HAVE I EVER HAD TO REPLACE BRAKES WITH SUCH LOW MILEAGE. DRIVING FOR 45 YEARS AND NEVER HAD THIS HAPPEN. THEY FIXED IT, NOT UNDER WARRANTY, SO I PAID. NOW, WITH A YEAR ON THE NEW BRAKE LININGS, THEY ARE MAKING NOISE AGAIN. VERY DISTURBING. THE VEHICLE IS USED FOR WORK AND IS NOT ABUSED, I AM THE ONLY ONE THAT DRIVES IT. DRIVING VANS FOR 30 YEARS AND THIS IS VERY DISAPPOINTING. *JB

Fuel System, Gasoline › Fuel Injection System
Filed Nov 16, 200564,216 milesCA

DT: THE CONTACT STATED WHILE DRIVING THE VEHICLE STALLED INTERMITTENTLY. THE VEHICLE STALLED WHEN SLOWING DOWN OR WHEN STOPPING. THE VEHICLE WAS TAKEN TO THE DEALERSHIP AND THE FUEL INJECTOR PUMP WAS REPLACED, THIS REPAIRED THE VEHICLE.*AK UPDATED 12/07/05. *JB UPDATED 12/7/2005. *NM

Tires
Filed Nov 2, 200550,000 milesIA

DT:THE CONTACT STATED THE LEFT REAR TIRE DEVELOPED A BULGE WITHIN THE TREAD. HE BROUGHT THE VEHICLE TO AN INDEPENDENT REPAIR SHOP, AND THEY REPLACED THE TIRE WITH A SPARE. WHEN HE RETURNED HOME THE VEHICLE WAS TAKEN TO A FIRESTONE DEALER, WHO DISCOVERED THERE WAS A COMPLETE BELT SEPARATION ON THAT TIRE. A SECOND INCIDENT LATER OCCURRED ON THE LEFT FRONT TIRE IN A SIMILAR FASHION. BOTH OF THE FAILED FIRESTONE TIRES WERE REPLACED WITH GOODYEAR TIRES. WHILE DRIVING THE RIGHT REAR REMAINING FIRESTONE TIRE BLEW OUT AT 75 MPH RESULTING IN DAMAGE TO THE VEHICLES FENDER AND BUMPER AREA. HE AVOIDED ANY COLLISION. HE TOOK PHOTOGRAPHS OF THE EXTENSIVE DAMAGE. NO FURTHER REPAIRS OR CORRECTIONS HAVE BEEN MADE AT THIS TIME. THIS IS A FIRESTONE STEELTEX R4S LT245/75/R16 LOAD RANGE E. THESE WERE THE ORIGINAL TIRES ON THE VEHICLE AT PURCHASE. *AK UPDATE 12/27/2005 - THE TIRES WERE MADE IN CANADA. *NM

Engine and Engine Cooling
Filed Oct 27, 200519,752 milesFL

CONSUMER 2002 CHEVROLET EXPRESS ENGINE ALMOST STALLED. CONSUMER HAD FUEL INJECTION SYSTEM CLEANED. *TS THE CONSUMER WAS TOLD THERE WAS CORROSION ON THE DISTRIBUTOR CAP AND ROTOR WHICH HAD ALREADY BEEN REPLACED TWICE. *JB

Tires › Temporary/Emergency Spare Tire
Filed Oct 12, 2005OH

DT: 2002 CHEVROLET EXPRESS. THE CONTACT STATED THE SPARE TIRE IS SECURED BY STRAPS ,AND ONE OF THE STRAPS CAME OFF THE VEHICLE. THERE WAS NO ONE BEHIND THE CONTACT'S VEHICLE. THEREFORE, NO ONE WAS INJURED. THE SPARE TIRE HAD BEEN USED A YEAR AGO. THE MANUFACTURER STATED THIS HAPPENED REGULARLY. ALSO, THE TIRE CAME OFF AT THIS TIME AND THAT TIRE WAS LOST. THE CONTACT PURCHASED ANOTHER TIRE. IT WAS LOCATED IN THE BACK OF THE VEHICLE. *AK

Service Brakes, Hydraulic › Power Assist › Hydraulic
Filed Sep 29, 200535,000 milesOH

SINCE THE 2002 CHEVROLET 1/2 TON CUSTOM VAN WAS PURCHASED IT HAS GIVEN ME BRAKE PROBLEMS. FIRST WAS THE ROTORS WHICH WAS SETTLED IN COURT, GENERAL MOTORS CUSTOMER SATISFACTION PROGRAM! THE BRAKES HAVE FAILED ABOUT 4 TIMES, 3 TIMES WITH ME AND ONCE WITH MY SON. THE STEERING ALSO GOES HARD. THE VAN WAS TAKEN TO THE CHEVROLET DEALERSHIP TO BE REPAIRED. THEY CLAIMED NOTHING WAS WRONG AND TO TAKE IT BACK. MY HUSBAND POINTED OUT THE NHTSA OFFICE OF DEFECTS INVESTIGATION 05V005000 BUT THEY COULD CARE LESS AND CLAIMED THEY LACK THE SKILL TO WORK ON BRAKE PROBLEMS. *NM

Electrical System › Ignition
Filed May 8, 20057,000 milesPA

THE VEHICLE SHUTS DOWN WITHOUT WARNING WHILE DRIVING, FOUND A GM SERVICE BULLETIN STATING TO REPLACE THE DISTRIBUTOR CAP AND ROTOR BUT HAVE DONE THAT NOW 4 FOUR TIMES BUT THIS DOESN'T CORRECT THE CAUSE JUST THE EFFECT. TO DATE IT HAS REDENDERED OUR VEHICLE UNDRIVEIBLE DUE TO IT'S UNRELIBILITY. GM ISN'T DOING ANYTHING TO HELP US OUR OUR WHEELCHAIR BOUND SON WHO RELIES ON THIS VEHICLE FOR MEDICAL APPOINTMENTS.

Electrical System › WiringFire
Filed Apr 26, 200514,628 milesPA

VAN IS USED IN A MUNICIPAL PARKS AND RECREATION DEPARTMENT FOR MAINTENANCE DUTIES. OPERATOR STARTED VEHICLE AT BEGINNING OF DAY TO WARM UP. OPERATOR LEFT THE VEHICLE. OPERATOR RETURNED APPROXIMATELY FIVE MINUTES LATER AND SAW SMOKE COMING FROM INSIDE THE PASSENGER AREA. OPERATOR CALLED 911 AND RETRIEVED A DRY POWDER EXTINGUISHER. OPERATOR SAW FLAMES COMING FROM AN AREA IN THE REAR OF THE DRIVER'S SEAT. OPERATOR TURNED OFF IGNITION AND USED EXTINGUISHER ON THE FIRE, PUTTING IT OUT. INVESTIGATION SHOWS AREA OF ORIGIN TO INSIDE THE DRIVER?S SIDE SEAT BELT CHANNEL. PLASTIC MOLDING COVERS THIS CHANNEL. A WIRING HARNESS IS LOCATED IN THIS CHANNEL. HEAVIEST BURN OF THE HARNESS IS DIRECTLY AT THE CONNECTION OF THE HARNESS TO THE DRIVER?S SIDE SEAT BELT MECHANISM LOCATED AT THE FLOOR. FIRE PARTIALLY CONSUMED HARNESS AND PLASTIC MOLDING. THERE ARE PICTURES OF THE DAMAGE AND HARNESS. HARNESS WAS CUT BACK TO CLEAN WIRING ON BOTH SIDES OF DAMAGED SECTION AND IS AVAILABLE FOR INSPECTION.*AK

Exterior Lighting › Brake Lights
Filed Apr 8, 200570,000 milesUT

1 AFTER 70000 MILES, THE GROUND CONNECTION IN THE BRAKE LIGHT/TAILLIGHT SOCKET BECOMES OXIDIZED FROM HEATING UP. 2. THE BRAKE LIGHTS QUIT WORKING. 3. I REMOVED A PLASTIC CLIP FROM THE BULB SOCKET AND ALLOWED THE GROUND WIRE TO ACQUIRE A NEW CONNECTION. 2002 CHEV EXPRESS VANPOOL VANS AT HILL AIR FORCE BASE, UTAH. *AK

Engine and Engine Cooling › Engine
Filed Mar 7, 2005IN

2002 CHEVROLET EXPRESS ENGINE LOST POWER AND REAR BRAKES CAUGHT ON FAILED. *BF THE CONVERTER WAS CLOGGED WHICH RESULTED IN THE ENGINE LOSING POWER. THE CHECK SERVICE ENGINE SOON LIGHT ILLUMINATED AND THE ENGINE MISSED ON ACCELERATION. THE DEALER REPLACED THE PLUG WIRE CAP ROTOR AND DISTRIBUTOR. THE CONSUMER HEARD A SCRAPPING NOISE COMING FROM THE REAR BRAKES AND VEHICLE SHOOK WHILE BRAKING. THERE WAS VIBRATION IN THE DRIVELINE ON ACCELERATION, THE BELT WAS REPLACED. VEHICLE CONSUMED EXCESSIVE AMOUNTS OF OIL. FLUID LEAKED FROM REAR AXLE, DEALER REPLACED THE REAR AXLE SEALS. THE DEALER REPLACED THE FUEL SENDER ASSEMBLY DUE TO STALLING. THE VEHICLE BATTERY WENT DEAD AFTER THE VEHICLE SAT OVERNIGHT. CLUTCH WAS LOUD AND PROVIDED NO POWER ON HOT DAYS, THE CLUTCH FAN WAS REPLACED. THE CONSUMER REQUEST THAT THE MANUFACTURER PROVIDE A REPLACEMENT VEHICLE OR REFUND THE FULL CONTRACT PRICE PLUS INCIDENTAL COST. *NM

Electrical System › Wiring › Front UnderhoodFire
Filed Feb 28, 200545,000 milesOH

VEHICLE WOULD NOT START. WENT INSIDE TO CALL TOW TRUCK TO HAVE IT TOWED TO MECHANIC. TURNED AROUND AND IT WAS ON FIRE. VEHICLE WAS NOT RUNNING;PARKED.

Structure › Body › Door
Filed Jan 11, 2005PA

FRONT DOORS DO NOT CLOSE TIGHTLY. SEVERE ROAD/WIND NOISE AT NORMAL HIGHWAY SPEEDS. NOISE WORSENED ON OUTSIDE DOOR WHEN TURNING (TURN TO RIGHT - LEFT DOOR NOISE INCREASES). I AM CONCERNED ABOUT THE INTEGRITY OF THE DOOR ATTACHMENT MECHANISM. PROBLEM EXISTED SINCE VEHICLE WAS NEW, BUT BECOMES MORE PRONOUNCED WITH TIME.*AK

Suspension › Front
Filed Dec 7, 200438,000 milesNY

WHILE DRIVING AT ANY SPEED VEHICLE PULLED TO THE LEFT. DEALER STATED THEY HAVE REPAIRED THE VEHICLE. CONSUMER INSISTED THAT AS A RESULT OF THE REPAIRS WHEN APPLYING THE BRAKES VEHICLE PULLED TO THE LEFT EVEN MORE.*AK

Electrical System › 12v/24v/48v Battery
Filed Aug 12, 200451,000 milesMO

THE CONSUMER SAW BATTERY ACID LEAKING FROM THE VEHICLE. THE MECHANIC REPAIRED THE PROBLEM ONCE, HOWEVER THE PROBLEM RESURFACED. *JB THE POSITIVE BATTERY POST BROKE AND CAUSED THE ACID TO LEAK DOWN THE SIDE OF THE ENGINE COMPARTMENT. THE DEALER WOULD NOT PROVIDE ANY FINANCIAL ASSISTANCE AND TOLD THE CONSUMER TO CALL AC DELCO. THE CONSUMER CONTACTED AC DELCO AND WAS TOLD IT WAS THE DEALER'S PROBLEM. *NM

Vehicle Speed Control › Cruise Control
Filed Jul 19, 2004PA

PROBLEMS WHILE USING CRUISE CONTROL ON VEHICLE.*MR WHEN THE CRUISE CONTROL WAS ENGAGED AND THE BRAKE PEDAL WAS PRESSED, THE VEHICLE TOOK A WHILE BEFORE RESPONDING AND REDUCING THE SPEED OF THE VEHICLE. WHEN THE CRUISE CONTROL WAS SET AT 65 MPH AND GOING DOWN GRADE, THE VAN WOULD PICK UP SPEED AND NEVER ADJUST BACK TO 65 MPH. IF THE SPEED WENT UP TO 70 MPH THE CRUISE CONTROL SET ITSELF AT 70 MPH. THE CONSUMER EXPERIENCED OTHER PROBLEMS WITH THE VEHICLE. THE VAN WOULD LOOSE POWER WHEN ACCELERATING. THE DEALER REPLACED THE PCM AND REPROGRAMMED IT. WHILE PERFORMING THE ENGINE DIAGNOSTIC THE TECHNICIAN FOUND THAT THE CAP AND ROTOR HAD MOISTURE IN THEM AND WERE CORRODED. THE VEHICLE'S BATTERY WAS ALSO REPLACED BECAUSE OF A DEAD CELL. *NM

Service Brakes, Hydraulic › Foundation Components › Disc
Filed Jul 11, 200431,000 milesAK

LOSS OF BRAKING EFFECTIVENESS, ON INSPECTION DISCOVERED THAT OEM FRONT AXLE GREASE SEALS HAD FAILED. FAILURE HAD CONTAMINATED BOTH LEFT AND RIGHT INNER DISC BRAKE PADS AND INNER SIDE OF BOTH FRONT ROTORS WITH AXLE GREASE. REPORTED TO DEALER SERVICE AND ASKED THAT THE FAILURE BE ENTERED INTO THE GM/CHEVY SYSTEM FOR INVESTIGATION AND CORRECTION. DEALER SERVICE DEPT. DENIED ANY OTHER INSTANCES OF THIS FAILURE EXISTED AND DECLINED TO REMEDY SEAL FAILURE OR BRAKE PAD DAMAGE UNDER WARRANTY. FRONT BRAKE PADS AND GREASE SEALS WERE REPLACED AT OWNER EXPENSE.*AK

Service Brakes, Hydraulic › Foundation Components › Disc › Pads
Filed Jul 10, 200435,000 milesAK

DURING PANIC STOP WITH EMPTY VEHICLE, BRAKE EFFECTIVENESS WAS INSUFFICIENT. BRAKE PEDAL TRAVELED TO MECHANICAL STOP WITH NO ANTISKID CYCLING, NO WHEEL SKIDS. EXAMINATION OF ROAD SURFACE AFTERWARDS SHOWED NOT EVEN A FAINT TRACE OF TIRE MARKS. VEHICLE WAS BEING OPERATED ON FREEWAY AND BRAKES HAD NOT BEEN USED FOR SEVERAL HOURS PRIOR TO THIS STOP. AN HOUR AFTER THIS INCIDENT AN INTENTIONAL PANIC STOP WAS MADE FROM 65MPH TO RECONFIRM, RESULTS WERE THE SAME. VEHICLE IS BEING SCHEDULED FOR INSPECTION BY DEALER. NOTE: THE ORIGINAL FRONT BRAKE PADS WERE REPLACED SEVERAL MONTHS AGO DUE TO THE OEM FRONT GREASE SEALS FAILING AND CAUSING GREASE CONTAMINATION OF THE FRONT INNNER DISC BRAKE PADS. *AK

Air Bags
Filed Jun 25, 200434,000 milesKY

WHEN DRIVING AT AN UNDETERMINED SPEED AIRBAG WARNING LIGHT APPEARED ON THE DASHBOARD. CONSUMER WILL TAKE THE VEHICLE TO THE DEALERSHIP FOR INSPECTION. *AK THE CONSUMER WAS TOLD THAT WATER CAUSED THE AIR BAG SENSOR TO FAIL. *NM

Steering › Gear Box (other Than Rack and Pinion)
Filed Apr 28, 20045,000 milesTX

THERE IS A KNOCKING IN THE STEERING. POOR STEERING CONTROL. DEALER REPLACED STEERING GEAR 3 TIMES AND THEN WAS TOLD BY GEN MOTORS NOT TO REPLACE IT AGAIN. THE PROBLEM STILL EXISTS. THE VEHICLE IS STILL IN WARRANTY. PRESENTLY AT A STANDOFF WITH GM. THEY WON'T FIX, I WON'T PAY.*AK

Power Train › Axle Assembly › Axle Shaft › Seal
Filed Apr 6, 2004NC

2002 CHEVY VAN/6.5 DIESEL LEAKS OIL FROM REAR AXLE SEALS. *LA

Engine and Engine Cooling › Engine › Diesel
Filed Apr 6, 200426,330 milesNC

2002 CHEVY VAN/6.5 DIESEL LEAKS OIL FROM OIL COOLANT LINES TOOK 3 TIMES TO FIX AND END RESULT WAS TO REPLACE THE OIL COOLER. *LA

Power Train › Automatic Transmission
Filed Mar 25, 200425,000 milesNY

THE VEHICLE'S TRANSMISSION HAS FAILED WITHOUT WARNING WHILE BACKING OUT OF THE DRIVEWAY. AS A RESULT THE VEHICLE COASTED SLOWLY INTO THE MIDDLE OF THE STREET. THE CAUSE HAS YET TO BE DETERMINED. PLEASE PROVIDE ANY ADDITIONAL INFORMATION. *NM

Tires › Sidewall
Filed Mar 8, 200427,000 milesMD

WHILE DRIVING AT 65 MPH REAR DRIVER'S SIDE TIRE BLEW OUT WITH WARNING. CONSUMER EXAMINED THE TIRE, AND DISCOVERED THAT THE TIRE BLEW OUT AT THE SIDEWALL.*AK

Structure › Frame and Members
Filed Mar 1, 20048,800 milesOH

RIGHT FRONT TIRE IS WEARING OFF ON OUTER EDGE OF TIRE. INSIDE DEPTH IS 8/32 OUTSIDE DEPTH IS 3/32, WITH ONLY APPROXIMATELY 8000 MILES ON TIRE. GOING ON THIRD SET OF TIRES WITH ONLY 17,000 ON IT. TOOK IT TO DEALER TWICE, DOES NOT KNOW WHAT IS WRONG WITH IT. 2002 EXPRESS COMMERCIAL CUTAWAY-12000 GVW. *AK

Suspension
Filed Feb 16, 200419,000 milesPA

VAN SUDDENLY DROPPED ON RIGHT FRONT SIDE AND STEERING PULLED VIOLENTLY RIGHT.*AK

Steering › Gear Box (other Than Rack and Pinion)
Filed Dec 4, 200330,000 milesTX

THE VEHICLE STEERING GEAR BOX FAILED. THE DEALER HAS REPLACED FOUR TIMES, HOWEVER PROBLEM STILL EXISTS. PLEASE PROVIDE ADDITIONAL INFORMATION. *PH

Tires › Tread/Belt
Filed Oct 22, 200310,353 milesCA

WHILE DRIVING, THE VEHICLE STARTED TO VIBRATE. THE VEHICLE WAS TAKEN TO A DEALER, WHO FOUND THE LEFT REAR TIRE TREAD WAS SEPARATING. *AK WHEN THE VIBRATION NOISE WAS HEARD A LOUD VIBRATION FOLLOWED BY A SOUND AS IF THE REAR END HAD FALLEN OFF. THE VEHICLE SWAYED. *SCC *JB

Exterior Lighting › Headlights
Filed Aug 25, 2003MI

CONSUMER NOTICED THAT WHEN HEADLIGHTS ARE TURNED ON TAIL LIGHTS FUSE BLOWS OUT INTERMITTENTLY.*AK

Steering
Filed Jun 24, 2003TX

WHILE TRAVELING ON THE HIGHWAY STEERING COLUMN HAS A LOT OF PLAY INSIDE OF THE STEERING WHEEL. *AK

Exterior Lighting
Filed Jun 2, 20037,000 milesLA

DEALERSHIP DON'T HAVE THE PARTS TO PERFORM THE OWNER NOTIFICATION FOR THE RUNNING BOARD LIGHTS.*AK

Electrical System
Filed May 2, 200315,542 milesTN

WHEN TAPPING THE GAS PEDAL LIGHTLY THE REDUCED ENGINE POWER AND SERVICE ENGINE SOON LIGHTS COME ON AND VEHICLE REMAINS RUNNING BUT LOOSES ALL POWER. *TT

Tires › Sidewall
Filed Mar 3, 200313,000 miles00

ALL 4 TIRES CONTAINED SPLITS ON THE SIDE WALL, CONSUMER WAS UNABLE TO DRIVE THE VEHICLE. *JB DOT #'S: VN 11 B1C 4101, 1501, 3801, AND 4001. SCC

Structure
Filed Feb 11, 2003CA

THE VEHICLE WAS NOT STABLE.*JB

Exterior LightingFire
Filed Feb 6, 200311,500 milesIL

2002 CHEVROLET EXPRESS VAN WITH EXPLORER CONVERSION - BURST INTO FLAMES WHILE IN OUR DRIVEWAY (ENGINE OFF). EXTENSIVE FIRE DAMAGE TO DRIVERS SIDE. EXTENSIVE SMOKE DAMAGE TO INTERIOR. FIRE MARSHALL STATES SMOKE PATTERN INDICATED FIRE ORIGONATED A BOTTOM OF DRIVER'S DOOR - LIGHT OR WIRING. OF NOTE, A "RECALL NOTICE" ARRIVED AT OUR HOME IN THE MAIL FOR THE RUNNING BOARD LIGHT WIRING HARNESS ON 2/5/03 WHICH WAS "DATED" 1/23/03.

Engine and Engine Cooling › Engine › Gasoline
Filed Feb 2, 200317,689 milesVA

CHECK ENGINE SOON LIGHT HAS EMITTED AND BEEN TO THE DEALER A MIN. OF FIFTEEN TIMES. THE DEALER CHANGED VARIOUS COMPONENTS IN HOPES OF REPAIR W/O REALLY KNOWING THE PROBLEM WITH THE VEHICLE. THE FACTORY WARRANTY HAS EXPIRED BUT THE EXTENDED WARRANTY IS IN PLACE BUT WON'T PAY FOR REPAIRS UNLESS SPECIFIC COMPONENTS IDENTIFIED. *JB

Complaints 1-50 of 56, newest first, reproduced as filed.

Across model years

Worst on record: 2000
YearComplaintsRecallsFiresDeathsAssessment
20260300Routine
20250400Routine
20241000Routine
20232100Routine
202113210Routine
202017100Routine
20198400Routine
201811610Routine
201721600Routine
201615620Routine
20158300Routine
201414700Routine
201322800Routine
201213602Fatalities reported
201112500Routine
201015510Routine
200910700Routine
2008141000Routine
200718410Routine
2006121600Routine
200523910Routine
200421720Routine
2003591170Routine
2002 — this page56030Routine
200145220Routine
200084110Routine
199968220Routine
199823220Routine
199729200Routine
199615330Routine
19951000Routine

Compare every Express year →

Reading this record

No unusual pattern of severe incidents in the complaint record.

Complaint counts track how many cars were sold and how long they have been on the road as much as they track quality. A common model from 2013 has had a decade to accumulate reports; a rare one from last year has not. The signal worth weighing is in the severity columns, in whether the same component keeps appearing, and in whether the manufacturer eventually opened a recall for it.

Most recent recall on file: none. Source: NHTSA Office of Defects Investigation.