2002 Chevrolet Express
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Owner complaints
56 complaints3 involved a fire
What owners report most
Latest complaints
- Electrical system › Instrument panel › Speedometer/odometer
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…
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
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…
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
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…
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 · Unknown or other · Visibility/wiper
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…
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
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 · Steering
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
Driver's side rear view mirror vibrates excessively. Hard to view items on the mirror. *Tr
- Engine and engine cooling
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…
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
Intake manifold gasket failure causing engine to seize at 69,700 miles. *tr
- Structure › Body › Door › Hinge and attachments
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
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
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 › Differential unit · Power train › Driveline › Driveshaft · Service brakes, hydraulic › Foundation components › Disc › Rotor
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…
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 warranty since I had taken it back to them within the warranty time, but they have given me nothing but grieve. I would appreciate any help I can get as I am afraid of the van now. *jb
- Service brakes, hydraulic · Tires · Visibility › Power window devices and controls
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 › Hoses, lines/piping, and fittings
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.
- Service brakes, hydraulic › Foundation components › Disc
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…
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
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
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…
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 · Fuel system, gasoline › Fuel injection system
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
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…
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
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…
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
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 › Wiring
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…
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
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
- Electrical system › 12v/24v/48v battery · Engine and engine cooling › Engine · Fuel system, gasoline · Power train › Axle assembly · Service brakes, hydraulic
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.…
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
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Hydraulic pump failres
Gm IS conducting a recall on all subject vehicles build between may 1999 and october 14, 1999.significant changes were incorporated into production in early october 1999, and vehicles built after that date have lower warranty failure rates.the complaint and warranty data appear to support the effectiveness of these…
Gm IS conducting a recall on all subject vehicles build between may 1999 and october 14, 1999.significant changes were incorporated into production in early october 1999, and vehicles built after that date have lower warranty failure rates.the complaint and warranty data appear to support the effectiveness of these changes. Gm made additional changes in november 1999, february 2000, may 2001, and february 2004.odi will continue to monitor this problem and will take further action, if warranted, in the future.for further technical details see the attached engineering analysis report.
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 11010544This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.
- 11009156This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester and Vehicle Data Recorder tools, giving website address and step by step instructions to complete the update.
- 11007744This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature.
- 11007743This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature.
- 11006621Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected modules (with some exceptions). The updating of modules is completed in parallel instead of the technician needing to update one module at a time. This allows a more streamlined approach for dealers and customers.
- 11006421GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the dealers to be more careful not to damage the transmissions during removal and to package the core properly for return.
- 11004761This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up.
- 11004557This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim.
- 11002312This service bulletin provides information for dealers/technicians on Service Programming System (SPS) Error Codes E4398, E4399, E4401, E4403, M4404, M4413, M6954, M6955, E4414, E4423, E4491, E4492, or E6961 and resolution information.
- 10252735This bulletin provides information for electrical ground repairs using new General Motors replacement fasteners with conductive finish.
- 10252163XM Audio Traffic And Travel Link Availability And Operation.
- 10251890This technical bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up.
- 10250775This service bulletin provides service information to technicians on guidelines to replace Oil Cooler, Oil Cooler Lines and Oil Tank if the engine was replaced where large amounts of debris has flowed throughout the oiling system.
- 10249980This Preliminary Information communication provides information to the technician about vibration complaints that are one of the most challenging complaints to accurately diagnose and repair. Technician will need to use Pico Oscilloscope Diagnostic Kit to effectively diagnosis vehicles. Technician should drive the vehicle will using the Pico Oscilloscope to record data. After the data is recorded it should be reviewed to determine the root cause of the concern. If a repair attempt made the concern better but not eliminated or had no affect at all, and are requesting assistance from General Motors Technical Assistance Center record another Pico file and save it to the computer. After the new Pico Oscilloscope data has been saved email the data to General Motors Technical Assistance Center in the subject line include ?Vibration? ?Business Associate Code? and the last 8 of the Vehicle Identification Number.
- 10249590This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim.
- 10249579This PI bulletin advises the technician on the proper way to install the pistons in an engine.
- 10249011This informational bulletin provides information for dealers/technicians on Headlamp, Tail Lamp, License Lamp or Fog/Driving Lamp Damage.
- 10248444Vehicle Recalls
- 10247780This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature.
- 10247681Information On Requests To Add OnStar Bluetooth Option.
- 10247552This service bulletin provides information on Concerns or Questions Regarding Installation of Dealer Installed Accessories.
- 10246952Programming And Activation Of Replacement OnStar Modules.
- 10246951Programming And Activation Of Replacement OnStar Modules.
- 10246631Expanded Availability for Remanufacture and Return (R&R) Electronic Control Modules
- 10246499Duramax Diesel Glow Plugs Difficult to Install Due to Carbon Buildup - New Glow Plug Bore Reamer Available
- 10245951Canadian Customers Unable To Place Calls And Turn By Turn Inoperative In The United States.
- 10245950Canadian Customers Unable To Place Calls In The United States
- 10244274This service bulletin provides information about the Hunter wheel Road Force balancers that should be utilized for all repairs requiring balance and Road Force measurement.
- 10244201This service bulletin provides information for dealers on how to submit a product information report (PIR) (Canada Only).
- 10242843The service bulletin advises the tech of a normal transmission shift condition and the delay in throttle response when the throttle plate is opened rapidly and advises the customer that it is normal for the delay.
- 10242298This Preliminary information communicates information that will need to be provided to TAC to aid in diagnosing if a vehicle comes in with misfire and DTC Codes P0300 - P0308 and/or P050D
- 10242262This service bulletin provides graphics, information and guidelines for engine component wear to assist service personnel as a guideline to perform necessary engine repairs and prevent unnecessary engine replacement.
- 10242252This technical bulletin provides information and a solution to a condition of Brake Pedal Moves or Self Applies at Full Turns.
- 10240793This Preliminary Information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get record a sound clip or take a video of the noise for assessment by engineering. Technician will need to call General Motors Technical Assistance Center for further assistance.
- 10240344This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.
- 10237671This Preliminary Information communication advises the technician that the Hydro-Boost is not serviceable and will need to be replaced if the brake pedal moves or applies on its own at a full turn.
- 10236164This Preliminary information communicates information that will need to be provided to TAC to aid in diagnosing if a vehicle comes in with misfire and DTC Codes P0300 - P0308 and/or P050D
- 10235802This diagnostic tip bulletin provides additional information on how to diagnose a possible valve, lifter or camshaft issue.
- 10235799This service bulletin provides information about the Hunter wheel Road Force balancers that should be utilized for all repairs requiring balance and Road Force measurement.
- 10234141This diagnostic tip bulletin provides additional information on how to diagnose a possible valve, lifter or camshaft issue.
Every Chevrolet Express model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.