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2003 Chevrolet Express Problems and Recalls
Owners filed 59 complaints with NHTSA about the 2003 Chevrolet Express, most often about the brakes (19% of complaints, typically around 25,000 miles). It is the 2nd most complained-about Express model year since 2000 and has 10 recalls.
Most common 2003 Chevrolet Express problems
Brakes
11 complaints · 19%Half of these problems showed up before 25,000 miles. Parts named most often: foundation components, pedals and linkages, disc, antilock/traction control/electronic limited slip.
Driver a noticed lack of pressure in brake pedal. The brake pedal went fully to the floor and resulted in less braking than expected. Driver reduced speed by downshifting to lower gears (automatic transmission) and pulled into first available parking area. By pumping the brakes and pulling into an uphill parking spot…
Dt: consumer was driving at 50 MPH and the brakes started vibrating. The problem first started around 6-4-05, and has gradually gotten worse. The consumer took vehicle it to the dealership twice. There was nothing done to fix the vehicle because it was not covered under the warranty. The consumer contacted the…
Fuel system
11 complaints · 19%Half of these problems showed up before 118,000 miles. Parts named most often: storage, fuel injection system.
The contact owns a 2003 Chevrolet Express. The contact stated that a small amount of fuel continuously leaked out of the fuel tank filler neck immediately after refueling. The vehicle was taken to an independent mechanic who stated that the fuel filler neck tube exhibited rust corrosion. The part was replaced. The…
The contact recently purchased a 2003 Chevrolet Express. The contact stated that the check engine warning light was illuminated on the instrument panel due to a corroded catalytic converter. The contact received notification of NHTSA campaign number: 12v388000 (fuel system, gasoline); however, the part to do the…
Electrical
10 complaints · 17%Half of these problems showed up before 27,500 miles. Parts named most often: wiring, horn, instrument panel.
The vehicle's horn and windshield wiper equipment failed intermittently. The cause had not been determined. Please provide additional information.
The panic alarm went off and couldn't be turned off initially. Dealer advised to bring vehicle in. Alarm went off when vehicle started for second time. Vehicle driven about 3 miles, engine shut down while driving. Pulled over, smoke poured from under hood, then flames until vehicle engulfed in flames. Vehicle totally…
Engine
6 complaints · 10%Half of these problems showed up before 15,500 miles. Parts named most often: cooling system.
My hose that connects to the engine to the radiator has cracked at least three times in the past two and half years, I have ask chevy on each occasion that I had to purchase it from the dealership, if there is a problem with how the hose is position so close to the exhaust pipe with no support to keep the hose away…
My 2003 chevy Express 2500 cargo van was in evening rush hour stop and go traffic. After reducing my speed to 10 MPH then attempting to accelerate. The vehicle stalled and began to idle rough and shut-off. I had to put the vehicle in neutral and restart in the middle of the interstate. I had to continue to shift into…
Transmission
6 complaints · 10%Parts named most often: automatic transmission, axle hubs.
Left front wheel bearing hub assembly separated causing thumping and grinding noise. Immediately drove to dealer for repairs. Upon inspection, it was found that the right front hub assembly had begiun to separate as well. Both front hub assemblies replaced under extended warranty.
Dt: contact owns 2003 Chevrolet Express g3500 passenger van. The van will accelerate on its own sporadically. This started around 7-20-05. It does it while stopping at stop light and it will also do it while driving on the highway. The idle speed control motor, throttle position sensor, cooling sensor, ECM, and the…
Body and structure
5 complaints · 9%Parts named most often: body.
During a family outing we were unable to close the right rear passenger door. Experienced difficulty closing door. After several attempts, I noticed the door was not aligned with the body of the car which prohibited the door latch to connect and close. The door would not close shut completely and has since knocked…
The contact owns a 2003 Chevrolet Express. The contact stated that the cable that held the seat belts together, located in the rear middle row, snapped without warning. As a result, the contact was concerned that, in the event of a crash, the seat belts would not secure properly and cause an injury. The contact also…
Air bags
4 complaints · 7%Parts named most often: frontal.
On the 2003 chevy Express van (box van), the passenger side air bag blew up without the vehicle being in motion. It blew up on the consumer's daughter who is 5 years old. The problem occurred when the consumer's daughter closed the door. The consumers daughter received numerous burns and lacerations on her arms and…
Vehicle was parked in our company parking lot, vehicle was not running and the key was not in the ignition. Employee was loading tools and equipment into rear of vehicle after completing a job. Side sliding door was open. Passenger air bag only deployed. Vehicle had not been a wreck.
Seat belts
4 complaints · 7%Parts named most often: front.
Driver side seat belt receiver malfunction - while inserting belt locking tab, red release button popped out - tried to reinsert button, mechanism jammed trapping me in seat; until I could thread myself out of belts. Part ordered.
This is regarding recall number 05113 (safety belts) for which we received a recall notice for our chevy Express van which is the foundation of our forest river 22' motorhome. I assume this affects the seat belts in the cab only. Our problem is that we have been unable to find a dealer who will repair this…
Complaints are owner reports to NHTSA, not verified defects. One complaint can name several components, so shares add up to more than 100%.
2003 Chevrolet Express recalls
Fuel system: filler pipe and cap
Risk: Significant corrosion may allow fuel to leak during refueling, and in the presence of an ignition source; there is an increased risk of fire.
Fix: Gm will notify owners, and dealers will install a new fuel filler neck, free of charge. The safety recall began on october 1, 2012. Owners may contact the chevrolet owner center at 1-866-694-6546 and gmc at 1-866-996-9463.
Full defect summary
General motors (gm) is recalling certain model year 2003-2004 chevrolet express and gmc savana vehicles, equipped with a left side cargo door, and originally sold or currently registered in connecticut, delaware, illinois, indiana, iowa, maine, maryland, massachusetts, michigan, minnesota, missouri, new hampshire, new jersey, new york, ohio, pennsylvania, rhode island, vermont, west virginia, wisconsin, and the district of columbia. Water and road contaminants may become trapped in the protective conduit that covers the fuel filler pipe and may cause the pipe to corrode.
Seat belts
Risk: In the event of a crash, a seat occupant may not be properly restrained increasing the risk of personal injury.
Fix: Dealers will inspect the buckles and, if found to be inoperative, the entire buckle assembly would be replaced. For buckles found to be operative, dealer will replace only the upper buckle cover. The recall will be conducted in phases. The first phase mailing began during march 2006. Owners may contact chevrolet at 1-800-630-2438 or gmc at 1-866-996-9463.
Full defect summary
On certain full-size passenger, cargo, or cutaway vans, the front and rear seat belt buckles will not latch or will not unlatch.
Seat belts: anchorage
Risk: The standard requires child seat lower anchorages in two seating positions for vehicles with three rear seating positions. The standard cab and cargo van vehicles, which only have front seating positions, have an air bag off switch to disable the front passenger air bag and do not have child restraint lower anchorages in the passenger seat. The standard requires passenger seat child seat lower anchorages in vehicles with an air bag off switch. However, the standard does not require vehicles with only front seating positions to have lower anchorage provisions if the vehicle is not equipped with
Fix: To bring the standard cab and cargo van vehicles into compliance, dealers will inject epoxy into the air bag off switch to prevent air bag activation, relocate the switch behind the instrument panel and then install a cover over the resulting opening. The sun visor label and owner's manual will also be changed. The correction for the extended cab vehicle will consist of changing the front passenger seat to a seat that has child restraint lower anchorages. The recall began on september 9, 2004. Owners should contact chevrolet at 1-800-630-2438 or gmc at 1-866-996-9463.
Full defect summary
Certain extended and regular cab pickup trucks and cargo vans converted to compressed natural gas (cng) fail to conform to the requirements of federal motor vehicle safety standard no. 225, 'child restraint anchorage systems.' these vehicles have one seating position, the center rear seat, equipped with child restraint lower anchorages.
Brakes: service brakes, hydraulic
Risk: Consequently, the valve o-ring seal may fracture. Steering efforts may be slightly increased while braking or parking. Under certain driving conditions, a fractured seal may require a slight increase in the applied brake pedal effort to achieve the same vehicle deceleration rate as prior to the seat fracture.
Fix: Dealers are to replace the hydro-boost relief valve. The recall began on june 18, 2004. Owners should contact cadillac at 1-866-982-2339; chevrolet at 1-800-630-2438; gmc at 1-866-996-9463; or hummer at 1-866-486-6376.
Full defect summary
Certain sport utility vehicles, pickup trucks, and passenger vans fail to comply with the requirements of federal motor vehicle safety standard no. 135, ?passenger car brake systems.? Some of these vehicles were produced with an out-of-specification brake hydro-boost housing relief valve bore.
Equipment: owners/service/other manual
Risk: This does not meet the requirements of the standard.
Fix: Owners will be provided with a supplement for their owner's manual. This supplement describes and shows the location symbols for the child restraint anchors that are located in the vehicle and on the child restraint or booster cushion. Owner notification began august 18, 2003. Owners should contact buick at 1-866-608-8080, cadillac at 1-866-982-2339, chevrolet at 1-800-630-2438, gmc at 1-866-996-9463, pontiac at 1-800-620-7668, or oldsmobile at 1-800-630-6537.
Full defect summary
Certain minivans, passenger and sport utility vehicles fail to comply with the requirements of federal motor vehicle safety standard no. 225, "child restraint anchorage system." the owner's manual does not explain the meaning of the location symbols for the child restraint lower universal anchorage system.
Lights: exterior lighting
Risk: If the socket assembly were to reach the point of melting, the occupants of the vehicle may notice an odor and smoke at the rear doors of the vehicle. If this odor and smoke were ignored, the plastic could ignite and a fire could occur.
Fix: Dealers will install a new sealed rear license plate lamp socket assembly. Owner notification began july 21, 2003. Owners should contact chevrolet at 1-800-222-1020 or gmc at 1-800-462-8782.
Full defect summary
Certain vans have a condition in which water may enter and corrode the rear license plate lamp socket. If the lamp socket were to corrode, the rear license plate lamp may operate intermittently or not at all, and the left rear tail lamp may become inoperative. The temperature of the license plate lamp socket could increase to the point that it may begin to soften and melt.
Seat belts: buckle assembly
Risk: This could result in increased risk of personal injury.
Fix: Dealers will replace the front driver and passenger side safety belt buckle. Owner notification began june 3, 2003. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact chevrolet at 1-800-222-1020 or gmc at 1-800-462-8782.
Full defect summary
On certain vans with a gross vehicle weight of less than 8,500 pounds, during a vehicle crash sufficient enough to deploy the safety belt pretensioner, the front safety belt buckles may not release after the vehicle crash, or alternately may eject the safety belt latch during the vehicle crash.
Steering: linkages
Risk: A separation could result in loss of vehicle control, and a crash could occur with prior warning.
Fix: Dealers will tighten the pitman arm nut to the proper specification. If the nut is missing, the dealer will install a new nut and tighten it correctly. Owner notification began december 10, 2002. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact chevrolet at 1-800-222-1020 or gmc at 1-800-462-8782.
Full defect summary
On certain vans with an 8,500 lb. Or 8,600 lb. Gross vehicle weight rating, the nut attaching the pitman arm to the steering linkage may not be tightened adequately resulting in a possible separation.
Steering: tie rod assembly
Risk: Separation of a tie rod can cause unexpected vehicle steering in some maneuvers and could cause a crash without prior warning.
Fix: Dealers will tighten the tie rod end nut and, if necessary, replace the tie rod end. Owner notification began november 27, 2002. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact chevrolet at 1-800-222-1020 or gmc at 1-800-462-8782.
Full defect summary
On certain vans, the right-hand tie rod end nut may not be tightened adequately. The nut can loosen resulting in separation of the tie rod from the steering knuckle.
Wheels and tires: lugs/nuts/bolts/studs
Risk: If this were to occur, the amber-colored ABS tell-tale lamp in the instrument panel would illuminate and the ABS system would be disabled. The driver would also notice a grinding noise, a decrease in the vehicle speed, and the steering will pull in the direction of the affected brake assembly. This could result in a loss of vehicle control, increasing the risk of a crash.
Fix: Dealers will inspect the wheel bearing assembly. If the inspection reveals a missing retaining nut, the wheel bearing assembly will be replaced. Owner notification began november 13, 2002. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact chevrolet at 1-800-222-1020 or gmc at 1-800-462-8782.
Full defect summary
Certain vans were built without a wheel bearing assembly retaining nut, which could lead to a possible bearing separation.
Recall repairs are free at any franchised dealer. Enter your VIN at nhtsa.gov/recalls to see which recalls are still open on your car.
NHTSA defect investigations
Fuel filler pipe corrosion/leakage
Summary
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
Hydraulic pump failres
Summary
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.
Questions about the 2003 Chevrolet Express
- What are the most common problems with the 2003 Chevrolet Express?
- By NHTSA owner complaints: brakes (11 complaints, typically around 25,000 miles); fuel system (11 complaints, typically around 118,000 miles); electrical (10 complaints, typically around 27,500 miles).
- How many recalls does the 2003 Chevrolet Express have?
- 10 recalls listed by NHTSA, the latest from August 8, 2012 (fuel system). Check your VIN at nhtsa.gov/recalls to see which ones are still open on your car.
- Is the 2003 a bad year for the Chevrolet Express?
- It is the 2nd most complained-about Express model year since 2000, with 59 complaints. Complaint counts are not adjusted for how many cars were sold, so popular years collect more of them, and the newest years have had less time to.