2003 Chevrolet Express 3500
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
Have the VIN?
Vehicles › Chevrolet › Express 3500 › 2003
These records cover every 2003 Chevrolet Express 3500. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Owner complaints
12 complaints1 involved a crash3 involved a fire2 injuries
What owners report most
Latest complaints
- Seat belts
TL* the contact owns a 2003 chevrolet express 3500. The contact stated that the seat belt buckles prematurely deteriorated to the point that the buckles failed to lock the seat belts to secure a passenger. The manufacturer indicated that a seat belt recall repair was performed in 2016, but the…
TL* the contact owns a 2003 chevrolet express 3500. The contact stated that the seat belt buckles prematurely deteriorated to the point that the buckles failed to lock the seat belts to secure a passenger. The manufacturer indicated that a seat belt recall repair was performed in 2016, but the contact explained that the remedy may not have provided a solution. The dealer (marshfield chevrolet, 14963 MO-38, marshfield, mo 65706, (866) 218-7896) was contacted. The contact was uncertain as to when the vehicle would be repaired due to the manufacturer stating that the recall had already been provided. The manufacturer issued four tsbs and three recalls for the seat belts. The approximate failure mileage was 80,000. *Tt *tr
- Electrical system
While driving vehicle, all electrical stopped, discovered that the ignition had turned off by itself and caused a loss of all power creating dangerous steering and stopping situation.. I was able to pull to the side of road and stopped vehicle. Took the truck to chevrolet dealer in sarasota rt. 41…
While driving vehicle, all electrical stopped, discovered that the ignition had turned off by itself and caused a loss of all power creating dangerous steering and stopping situation.. I was able to pull to the side of road and stopped vehicle. Took the truck to chevrolet dealer in sarasota rt. 41 and bee ridge and was told it was not part of recall. This does not make sense, it has the same symptoms as the other defective vehicles maybe they don't want to increased their problems with another year and model. Please help, I am unable to drive my truck for work and am losing money and customers, as I am a general one man contractor. Please advise. *tr
- Engine
TL* the contact owns a 2003 chevrolet express 3500. The contact stated that after starting the vehicle the transmission failed to shift into gear. The vehicle was towed to the dealer who stated that the cause of failure was unknown. However, the technician stated that the maf censor needed to be…
TL* the contact owns a 2003 chevrolet express 3500. The contact stated that after starting the vehicle the transmission failed to shift into gear. The vehicle was towed to the dealer who stated that the cause of failure was unknown. However, the technician stated that the maf censor needed to be replaced. The vehicle was repaired but the failure recurred. The vehicle was taken back to the dealer who stated that the vehicle needed the catalytic converters replaced. The vehicle was repaired. The manufacturer was notified of the failure. The failure mileage was 58,500.
- Fuel/propulsion system
When the vehicle fuel tank IS filled, gas fumes are detected and some fuel can be seen on the bottom of the tank (a few drops of fuel). as the tank contents lower the smell and leak goes away. an access hole on the side of the van reveals that the tank has a small leak where the plastic fill neck…
When the vehicle fuel tank IS filled, gas fumes are detected and some fuel can be seen on the bottom of the tank (a few drops of fuel). as the tank contents lower the smell and leak goes away. an access hole on the side of the van reveals that the tank has a small leak where the plastic fill neck was bonded to the tank. the steel fill neck and rubber connection look fine. this IS a conversion van w/o a left hand door. this vehicle was bought from a southern climate area and IS only recently been brought to a northern climate so corrosion IS not suspected. since I see no recall or many complaints, I am looking to repair or replace the tank. currently looking for a seal material that could be applied to the leak and that works on polyurethane and resists fuel. have not found one. The vehicle IS well out of warranty but this does seem to present a safety issue. short term solution IS to not fill the tank. *Tr
- Seat belts
TL* the contact owns a 2003 chevrolet express 3500. the contact stated that the front driver and rear seat belts would not latch and one of the rear seat belts was completely inoperable. the dealer and manufacturer were contacted and advised that the vehicle was previously repaired under nhtsa…
TL* the contact owns a 2003 chevrolet express 3500. the contact stated that the front driver and rear seat belts would not latch and one of the rear seat belts was completely inoperable. the dealer and manufacturer were contacted and advised that the vehicle was previously repaired under nhtsa campaign ID number: 05v558000 (seat belts). the recurring failure was not repaired. the failure mileage was 65,030 and the current mileage was 65,040. updated 01/20/12*lj updated 01/20/12
- Fuel system, gasoline · Fuel system, gasoline › Storage › Tank assembly › Filler pipe and cap
Gas leaking from fuel filler pipe onto inside of wheel well and ground. Examination reveals design of pipe assembly (metal pipe inside corrugated plastic tube), traps condensation and water around metal pipe guaranteeing rust and leaks. May be worse in high humidity regions but same assembly IS…
Gas leaking from fuel filler pipe onto inside of wheel well and ground. Examination reveals design of pipe assembly (metal pipe inside corrugated plastic tube), traps condensation and water around metal pipe guaranteeing rust and leaks. May be worse in high humidity regions but same assembly IS open to water splashed up from road. this may only occur on cargo vans with left hand door option. updated 08/11/11 *bf *kb
- Electrical system
Wire harness fire. Water got into the end of one of the connectors from the wire harness going into the trasmission. The result of the water getting into the transmission caused an electrical fire and caused a short in the transmission and engine wire harness, the final result was the wire harness…
Wire harness fire. Water got into the end of one of the connectors from the wire harness going into the trasmission. The result of the water getting into the transmission caused an electrical fire and caused a short in the transmission and engine wire harness, the final result was the wire harness was completely burned up. There was evidence of glueing the connectors years ago.i if the connectors are not sealed, it IS possible for water to enter and short out connectors and other electrical components. *tt
- Air bags › Frontal
I was in an accident traveling 65 mph and hit another vehicle broadside and the air bag never deoloyed. The vehicle was totaled. Its a 2003 3500 chevy van. *Tr
- Service brakes, hydraulic
Tl*the contact owns a 2003 chevrolet express 3500. the contact stated that the vehicle made a grinding noise. he inspected the vehicle and discovered that the front and rear brake pads and rotors were corroded. a report was filed with the manufacturer and they stated that they could cover 50% of…
Tl*the contact owns a 2003 chevrolet express 3500. the contact stated that the vehicle made a grinding noise. he inspected the vehicle and discovered that the front and rear brake pads and rotors were corroded. a report was filed with the manufacturer and they stated that they could cover 50% of the repair cost for the rotors; however, the contact would be responsible for the brake pads and any additional costs. the vehicle IS out of warranty. the manufacturer also stated that if the vehicle IS not driven regularly, the components could corrode. the vehicle has not been repaired. the current and failure mileages were 38,000.
- Structure › Body
I purchased my 2003 chevy express 3500 in 2003. On the passenger side of the van there IS a front passenger door and are two passenger doors on the side of the van. In five years time I have had trouble with the side passenger door hinge seizing up and now I can't open the left side door and it IS…
I purchased my 2003 chevy express 3500 in 2003. On the passenger side of the van there IS a front passenger door and are two passenger doors on the side of the van. In five years time I have had trouble with the side passenger door hinge seizing up and now I can't open the left side door and it IS improperly seated in the door opening, I now do not have a tight seal and the right side door cannot close properly. This poses a safety hazard because in an emergency the left side door cannot be opened. *tr
- Visibility · Visibility › Defroster/defogger/hvac system
2003 chevy express. turned on the rear defroster. the rear passenger side window caught fire and began burning. pulled the vehicle to the side of the road and another car pulled over with me. the window continued to burn, and then exploded in my face. the fire went out and the window had shattered into fragments. *tr
- Electrical system › Wiring › Front underhood
Fire to vehicle . *Jb
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 3500 model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.