2003 Chevrolet Express 1500
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Chevrolet › Express 1500 › 2003
These records cover every 2003 Chevrolet Express 1500. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
1 recall names the 2003 Chevrolet Express 1500. Newest first.
Certain replacement fuel filters, fram brand name p/n g3727, with date codes x52911 through x60801 sequentially or x600141 and a mexico country or origin marking on the fuel filter housing manufactured from october 18, 2005, through march 21, 2006, sold for use on the vehicles listed above and on certain school buses. (to see the school bus engine sizes…
Risk and remedy
Risk
This condition may cause an inadequate seal at the connection, potentially leading to a fuel leak. In the presence of an ignition source, a fire could occur.
Remedy
Honeywell will notify owners and replace the fuel filters free of charge. the recall began on october 18, 2006. owners may contact fram customer service at 1-800-890-2075 (option 1).
Owner complaints
18 complaints2 involved a fire1 injuries
What owners report most
Latest complaints
- Structure › Body
Hinges broke; doors are unsafe.
- Fuel/propulsion system
Corroded and leaking fuel filler neck. Foolish design involving dissimilar metals held in contact and surrounded with a conduit which holds water and road salt. Design IS destined for failure. Gm has a partial recall for the snow belt. Such a foolish design should be fixed everywhere as it IS just a matter of time until failure.
- Structure › Body
The passenger side swing doors are very hard to open and shut and the drivers side swing doors are in the initial stage of this. The passenger swing door that IS first to open (right) does not want to open and doesn't want to shut. I have to force it. The second door (left) IS getting worse as…
The passenger side swing doors are very hard to open and shut and the drivers side swing doors are in the initial stage of this. The passenger swing door that IS first to open (right) does not want to open and doesn't want to shut. I have to force it. The second door (left) IS getting worse as well. This IS causing the interior light pin in the door jam to not push in all the way, therefore; the lights will not shut off.
- Fuel/propulsion system
TL* the contact owns a 2003 chevrolet express 1500 van. The contact stated that when fueling the vehicle, fuel sprayed from the filler neck. The dealer diagnosed that fuel filler pipe needed to be replaced. The vehicle had not been repaired. The manufacturer had not been notified. The approximate failure mileage was 107,000.
- Fuel/propulsion system
TL* the contact owns a 2003 chevrolet express 1500. The contact stated that fuel was leaking from under the vehicle. The vehicle was taken to the dealer and to an independent mechanic for diagnostic testing. The technician and the mechanic advised that the return and delivery fuel lines would have to be replaced due to corrosion. The vehicle was not repaired. The approximate failure mileage was 148,000.
- Fuel/propulsion system
On a few occasions prior to locating a leak, I noticed a gasoline smell. finally when filling earlier this month, I saw a lot of leaking coming out of the fuel filler tube, between the metal tube and the plastic cover surrounding the tube. when I got home, I cut off the plastic tube about halfway…
On a few occasions prior to locating a leak, I noticed a gasoline smell. finally when filling earlier this month, I saw a lot of leaking coming out of the fuel filler tube, between the metal tube and the plastic cover surrounding the tube. when I got home, I cut off the plastic tube about halfway and found a static wire running the length of the tube. everywhere, where this wire touched to metal pipe, it was corroded completely through. the static wire IS of a different material and was not corroded. Presently I have wrapped the tube with a gasoline resistant tape. But, I will have to replace the tube soon. The local dealership has quoted approx. $241.00 without installation. Are there other instances like this and IS there a recall I'm not aware of. Thank you for your time. *tr
- Fuel system, gasoline
For sometime, there was a smell of gasoline when filling this van, which I just attributed to a vapor release when the tank was full. recently, I notice gas leaking under the van when filling at the gas station. the gas leaks in and around the brake lines. this van IS a 2003 chevrolet express…
For sometime, there was a smell of gasoline when filling this van, which I just attributed to a vapor release when the tank was full. recently, I notice gas leaking under the van when filling at the gas station. the gas leaks in and around the brake lines. this van IS a 2003 chevrolet express 1500 with left hand door option. this IS my family vehicle and in researching this problem further, I understand it to be a known problem and a design flaw, where the fuel fill hose rusts. this needs a recall with immediate attention. *tr
- Fuel system, gasoline
I was refueling my van and gas started pouring out from the bottom. After looking I discovered the fuel filler neck was rusted thru. The van only has 64K miles. I replaced it myself at this time. There was no collision damage....simply heavy corrosion. *tt
- Fuel system, gasoline · Fuel system, gasoline › Storage › Tank assembly › Filler pipe and cap
TL* the contact owns a 2003 chevrolet express 1500. The contact stated that after refueling, he noticed an overpowering fuel odor. The contact further inspected the vehicle and found that the fuel tank was leaking and rusted. The vehicle was inspected by the dealer and they advised the contact that…
TL* the contact owns a 2003 chevrolet express 1500. The contact stated that after refueling, he noticed an overpowering fuel odor. The contact further inspected the vehicle and found that the fuel tank was leaking and rusted. The vehicle was inspected by the dealer and they advised the contact that the gasoline filler tube needed to be replaced. The vehicle was not repaired. The manufacturer was contacted and they offered no assistance. The failure mileage was approximately 64,000. updated 02/13/12
- Fuel system, gasoline
Gas filler tube rusted through and gasoline leaked every time I refueled. This was not a small hole. The metal on the whole tube broke down causing fuel to leak and creating a fire hazard. updated 08/11/11 *bf updated 3/08/2012 *ln *tr
- Seat belts
Drivers seat belt became stuck and I had to limbo to get out of my express conversion van. I had to bag on it to make it release. It doesn't latch anymore and I need to replace the bottom section. *tr
- Fuel system, gasoline
Fuel leaking from fuel tank filler tube when filling gas tank. *Tr
- Seats
Seat back of drivers seat failed and now seat will not stay in the upright position. The vehicle was not involved in a collision and this occured while driving. *Tr
- Engine and engine cooling
Tl*the contact owns a 2003 chevrolet express 1500. on september 7, 2008, the contact started the vehicle and heard a knocking sound. the sound originated from the engine and persisted throughout the day. he checked the oil and noticed that there was only one quart. he placed more oil in the…
Tl*the contact owns a 2003 chevrolet express 1500. on september 7, 2008, the contact started the vehicle and heard a knocking sound. the sound originated from the engine and persisted throughout the day. he checked the oil and noticed that there was only one quart. he placed more oil in the vehicle. the failure did not prevent him from accelerating. the contact took the vehicle to a local repair shop and was informed that the lifters and push rods were defective, which caused the engine to fail. the vin was unknown. the current and failure mileages were 138,000.
- Latches/locks/linkages · Seat belts
(1)Seat belt will not latch. Seatbelt latch opens without warning. (2)THE side cargo door hinges are faulty and hard to open. Opens without warning. *tr
- Electrical system
At 4:30 a.m. On the morning of feb 13 2008 was awoke to flames flickering on bedroom wall it was my 2003 regency conversion van going up in smoke no apparent reason but it did start in the fuse box area maybe the same issue as the horn problem the week before had the same problem of horn going off in the middle of the night but there was no fire at that time. *tr
- Steering › Linkages › Tie rod assembly
During routine maintenance of my 2003 chevy express van, I noticed that both inner tie rods have excessive end play in them, left inner and right inner. I do not believe this IS a normal wear problem and IS a very dangerous concern. *tr
- Electrical system › Horn · Electrical system › Wiring
Tl*the contact called regarding a 2003 chevrolet express 1500. the contact IS the physical damage inspector for an insurance company. he stated that the vehicle was parked when the horn began to sound. he stated that the horn IS also used as an intruder alarm. shortly after, flames began to…
Tl*the contact called regarding a 2003 chevrolet express 1500. the contact IS the physical damage inspector for an insurance company. he stated that the vehicle was parked when the horn began to sound. he stated that the horn IS also used as an intruder alarm. shortly after, flames began to rise from the hood. the vehicle was taken to the dealer and they stated that it was not a warranty related failure. the dealer also stated that the wire that runs from the horn relay to the actual horn in the steering wheel column super heated, which caused the fire. a police report was filed. the purchase date and mileages were unknown. return usps, made 2ND attempt 08/04/07 failed. *bf
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Fuel Filler Pipe Corrosion/Leakage
On August 7, 2012 General Motors (GM) notified the Office of Defects Investigation (ODI) that it will conduct a safety related recall for model year (MY) 2003-2004 Chevrolet Express and GMC Savana vehicles.The recall affects vehicles equipped with a left side cargo door and that were originally sold or currently…
On August 7, 2012 General Motors (GM) notified the Office of Defects Investigation (ODI) that it will conduct a safety related recall for model year (MY) 2003-2004 Chevrolet Express and GMC Savana vehicles.The recall affects vehicles equipped with a left side cargo door and that were originally sold or currently registered in the corrosion or salt-belt states of Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia and Wisconsin. Dealers are to install a new fuel filler neck. Consumer notification letters will be sent in early October 2012, when sufficient parts are available. ODI has received 12 complaints alleging unique incidents of fuel leakage during refueling of a subject vehicle. Eleven of the complaints occurred on Chevrolet Express vans, and 1 of the complaints involved a GMC Savana. All vehicles were equipped with the left side cargo door option. For vehicles so equipped, water and road debris can become trapped in the protective conduit that covers the fuel filler pipe and may subsequently cause the pipe to corrode. If the corrosion creates a significant perforation in the pipe, fuel may leak onto the ground while refueling the vehicle. An illuminated Check Engine light (on some vehicles) or the presence of fuel odor may also act as precursors to fuel leakage. Fuel in the presence of an ignition source could cause a fire to occur. In their response to ODI's information request, GM reported 24 owner reports and 1 field report alleging fuel filler pipe failure/corrosion in the subject vehicle population. Six additional records were also provided that included the replacement of the fuel filler pipe, however not enough information existed to determine a relation to the alleged problem. After further review of the reports, ODI determined that a total of 27 individual GM reports were related to filler pipe corrosion. The complaints received from both ODI and GM primarily occurred in the corrosion states. During the investigation, the scope of the subject vehicle population was expanded to include MY 2004 Express vans, and MY 2003 and 2004 GMC Savana vans (with V6 engines) also equipped with left hand side door options, since the Savana vans also utilize the same, or substantially similar fuel filler pipe configuration. GM subsequently modified the design of the fuel filler pipe on vehicles equipped with side doors to correct the corrosion concern, so these vehicles do not have the defect issue.The affected vehicle population shown above reflects the total number of vehicles registered in the salt-belt states listed in GM's defect information report (DIR). Prior to the safety recall announcement, GM had issued a special coverage adjustment for vehicles in these states, during which a total of 771 repairs were made. Accordingly the vehicle population noted in the DIR reflects that of the remaining vehicle population.The investigation is closed based on GM's announcement of safety recall 12V388. The reports cited above can be reviewed online at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers: 10463398, 10459328, 10456403, 10453725, 10445925, 10443143, 10441615, 10413568, 10413214, 10411911, 10353717, 10259377.
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.
- 11007208This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed for the vehicle in question and its applications. Technician should not use the information that is provided by the antilock braking system tire size selection.
- 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.
- 11000576This Warranty Administration bulletin provides retail and wholesale service personnel with the policies/procedures and the warranty transaction submission procedures that support the Personal Property Damage process.
- 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.
- 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
- 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
- 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.
- 10244214This informational bulletin provides information for the IPC odometer programming method quick reference guide.
- 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.
- 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.
- 10240344This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.
- 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.
- 10234110This service bulletin provides service information on new torque specification and installation procedure for ACDelco Spin-On Oil Filters.
- 10232287This warranty administration bulletin provides information regarding the field action courtesy transportation policy.
- 10232156This service bulletin provides information for dealers/technicians on OnStar Module 2G Sunset Information.
- 10232136This service bulletin provides information for dealers/technicians on Exterior Lamp Condensation and Water Leaks and Replacement Guidelines.
- 10230605This service bulletin provides information for dealers/technicians on OnStar Module 2G Sunset Information.
- 10228906This Warranty Administration bulletin provides retail and wholesale service personnel with the policies/procedures and the warranty transaction submission procedures that support the Personal Property Damage process.
- 10228888This service bulletin provides diagnostic tips/steps on testing for possible EVAP leaks in the system to correct a customer concern of an MIL Illuminated with DTCs P0442 and/or P0455 Set.
Every Chevrolet Express 1500 model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.