66 of the
856 complaints filed about the Chevrolet Express
are about the fuel system —
8% of everything owners reported.
The worst model year for it is 2003.
Vehicle broke down with a crank no start condition. Verified no fuel pressure. Diagnostics revealed no continuity between tank fuel pump positive lead at fuel pump relay, and ground. Removed fuel tank, disconnected fuel pump wiring harness, and found burned pin at positive terminal of fuel pump and mating harness connector. Harness displayed significant distortion and charring consistent with a poor connection.
NHTSA complaint #11756037 — an unverified report by a vehicle owner.
The contact owns a 2024 Chevrolet Express. The contact stated that while attempting to accelerate, the vehicle hesitated, jerked, and stopped unexpectedly. There were no warning lights illuminated. The vehicle was serviced by an independent mechanic who determined the failure was associated with DTC: P129F-00 (Fuel pump drive control module). The part was replaced. The contact stated that the vehicle was in a fleet of vehicles for the school district. The local dealer was contacted, but the vehicle was not diagnosed or repaired. The manufacturer was contacted, and the contact was referred to the NHTSA Hotline for assistance. The failure mileage was approximately 56,837.
NHTSA complaint #11709863 — an unverified report by a vehicle owner.
Vehicle is upfitted as a school bus. Forward fuel tank strap failed in operation. Our company operates more than 100 of these vehicles and we experience a failure of fuel tank straps at a rate of about one vehicle per month. If the 2nd strap would also fail the gasoline tank would become dislodged and present a re hazard. This is even more critical as these vehicles are carrying students as a school bus. We perform visual inspections of the straps at 6 month intervals (per Pennsylvania these vehicles are subject to Semi-Annual State Inspection). There were no symptoms of the problem before this failure. There are never symptoms of the problem.
NHTSA complaint #11656226 — an unverified report by a vehicle owner.
Vehicle is upfitted as a school bus. Forward fuel tank strap failed in operation. Our company operates more than 100 of these vehicles and we experience a failure of fuel tank straps at a rate of about one vehicle per month. If the 2nd strap would also fail the gasoline tank would become dislodged and present a fire hazard. This is even more critical as these vehicles are carrying students as a school bus. We perform visual inspections of the straps at 6 month intervals (per Pennsylvania these vehicles are subject to Semi-Annual State Inspection). There were no symptoms of the problem before this failure. There are never symptoms of the problem before any failure. Failed fuel tank straps on this were repaired by GM Dealer (Faulkner GMC, 705 Auto Park Blvd, West Chester, PA 19382) (Invoice #677658 - Invoice Date Feb 25 2025).
NHTSA complaint #11649646 — an unverified report by a vehicle owner.
Fuel Pump Control Module failed in vehicle with only 26,000 miles. No warning light came on. No previous issue. Vehicle stalled while driving speed limit, all control of steering and braking was lost and vehicle did not restart. Needed to have vehicle towed. Vehicle was diagnosed by a dealership. Part unavailable, backordered and have been without vehicle for over 2 weeks. Awaiting invoice for repair
NHTSA complaint #11617913 — an unverified report by a vehicle owner.
The contact owns a 2014 Chevrolet Express. The contact stated that while driving at an undisclosed speed, there was an abnormal fuel odor coming from the vehicle with several unknown warning lights illuminated. The contact had the vehicle towed to an independent mechanic where it was discovered that the fuel regulator was leaking. The manufacturer was notified of the failure and the contact was informed that the vehicle was not included in NHTSA Campaign Number: 14V500000 (Fuel System, Other). The vehicle was then towed to a dealer however, the dealer refused to service the vehicle. The vehicle was not repaired and remained with the dealer. The failure mileage was approximately 20,000.
NHTSA complaint #11567850 — an unverified report by a vehicle owner.
The contact owns a 2021 Chevrolet Express. The contact stated while driving out of the driveaway, the vehicle shut off inadvertently and failed to restart. The vehicle was towed to the dealer, where it was diagnosed that the fuel pump control module had failed and needed to be replaced. The vehicle was repaired; however, the failure persisted. The contact stated while driving 75 MPH, the failure recurred. The contact was unable to pull to the side of the roadway. The vehicle was towed to a second dealer, Auto Gallery Chevrolet Buick GMC (1415 Lafayette Pkwy, LaGrange, GA 30241) and the contact was informed that the dealer could not repair the vehicle. The vehicle was not repaired. The manufacturer was notified of the failure and informed the contact that the vehicle would be towed to another dealer. The failure mileage was approximately 5,000.
NHTSA complaint #11558742 — an unverified report by a vehicle owner.
The fuel pump power control module in this vehicle has caused the fuel pump to fail or operate intermittently, interrupting the flow of fuel to the engine. When the engine does not receive adequate fuel, the vehicle has unexpectedly stalled. This has happened several times. At times has seen a check engine light or experienced a rough running engine. The vehicle may also be A vehicle stall without warning could increase the risk of a crash, especially at high speeds. This vehicle has been taken to a GM or Chevrolet service center twice for this problem. The first time, the fuel pump module was replaced. The second time, there was wiring that was bad that had to be traced down that was related to the fuel pump module failing. It has now happened a third time, while driving down the road, the vehicle suddenly shuts off. It has less than 5,000 miles on the engine. This vehicle has been out of service to the owners for an inordinate amount of time since ownership. It was in the shop 38 days the 2nd time. It is now taking a very long time with GM customer care for them to even find a place to work on it and to have it towed there. This has happened several times. I have created a log of events. I will enter the first time that this happened below and then provide other data.
NHTSA complaint #11542691 — an unverified report by a vehicle owner.
2008 Chevrolet Express van stalled while driving. I was able to coast over to the highway's shoulder. Van restarted after a few attempts and I resumed driving towards a small town ahead. Van re-stalled in the town. Attendant at small garage said the van had diagnostic codes for the fuel system. I was able to idle the van to a Chevrolet dealership for servicing. The dealership diagnosed and replaced the Fuel Pump Driver Module (part 20759945) (aka: Chassis Electronic Control Module) 17-days later, for about $650. Why wasn't I given notice and serviced under GM Recall Bulletin 14515 or 14515B, which specifies my van and that exact part? The dealership said my van is not part of that recall. The NHTSA site says my van has no pending recalls. The problem is serious enough that the Recall Bulletin applies regardless of years or miles. Even if an affected vehicle came in for an oil change, it can't be released until 20759945 is replaced. Van now suffering from code for upset oxygen sensor. VAN IS SPECIFIED IN THE RECALL BULLETIN BUT WAS NOT ADDED TO THE DATABASE OF VEHICLES TO BE SERVICED! The contact stated that the dealership told them that the module failure "probably" did not ruin the catalytic converters. The contact said they would look into the issue within their home garage.
NHTSA complaint #11522790 — an unverified report by a vehicle owner.
While driving engine inexplicably shut off leaving us without power steering or brakes and unable to safely navigate off of the roadway. Fault: Fuel Pump Control Module GM representative stated they are seeing numerous failures of these components
NHTSA complaint #11519585 — an unverified report by a vehicle owner.
NHTSA Campaign Number: 12V388000. I have this problem. A leaking fuel line due to corrosion. I drive in the Cascade MT's of Washington state. my line now leaks excessively on fill up.
NHTSA complaint #11454777 — an unverified report by a vehicle owner.
The contact owns a 2015 Chevrolet Express. The contact stated that she could not place compressed natural gas into the tank of her vehicle. The contact was able to find the required gas in another state; however, the vehicle ran out of gas on the return home. The contact had initially towed the vehicle to a local dealer and was informed that they did not have an available service technician to repair her vehicle. The contact then called Weston Buick GMC (22555 SE Stark St, Gresham, OR 97030) where she towed the vehicle after she was assured that the vehicle could be serviced by the dealer. After two weeks of remaining in the dealer's possession, the contact was also informed that the dealer did not have a service technician that could service her vehicle. The contact then called the manufacturer who contacted six dealers within her area and no dealer could help. The vehicle had yet to be repaired. The failure mileage was approximately 20,000.
NHTSA complaint #11443768 — an unverified report by a vehicle owner.
I HAVE A FLEET OF 2011-2015 CHEVROLET EXPRESS DIESEL CARGO VANS FOR MY BUSINESS. EACH OF THEM ARE ON THEIR 3RD REPLACEMENT OF THE DEF TANK HEATER KIT GM P/N 84412924. IT SEEMS TO DIE AFTER USE IN THE 80,000 MILE RANGE. SEEMS TO BE A POORLY DESIGNED PART HAVING TO DO THIS.
NHTSA complaint #11230998 — an unverified report by a vehicle owner.
COMPLAINT 11102768 FILED PREVIOUSLY FOR CRANKSHAFT SENSOR AND CAMSHAFT SENSORS. NEW COMPLAINT : VEHICLE WOULD NOT START 7/11/2018. CALLED CHEVY DEALER. WAS TOLD TO REMOVE AND REPLACE RELAY IN FUSE BLOCK. VEHICLE STARTED. DEALER INFORMED US THAT THEY HAVE HAD TO REPLACE FAULTY FUSE BLOCK IN MANY SIMILAR VEHICLES. OUR VEHICLE IS A 2013 CHEVY EXPRESS CUTAWAY 4500. MODEL G33803 159" 6.0 GVW 14,200. IT IS A FOREST RIVER SUNSEEKER RV. THEY HAVE HAD TO REPLACE THEM IN AMBULANCES AND OTHER HEAVY TRUCKS. THE PART NUMBER FOR THE FUSE/RELAY BLOCK IS 22767373 THIS ITEM IS NOT ON RECALL LIST. PLEASE HELP. THE VEHICLE HAS JUST OVER 9000 MILES ON IT AND THESE ITEMS ARE MAJOR, POTENTIALLY DANGEROUS PROBLEMS. THANK YOU
NHTSA complaint #11111685 — an unverified report by a vehicle owner.
TL* THE CONTACT OWNS A 2011 CHEVROLET EXPRESS. WHILE DRIVING AND SLOWING DOWN, THE VEHICLE AGGRESSIVELY DOWNSHIFTED, THE BRAKE PEDAL INDEPENDENTLY DEPRESSED, AND THE VEHICLE LUNGED FORWARD. THE CONTACT WAS CONCERNED ABOUT THE HARD UPSHIFTS AND DOWNSHIFTS OF THE TRANSMISSION. WHEN THE ENGINE WAS TURNED OFF AND RESTARTED AFTER APPROXIMATELY 15 MINUTES, THE VEHICLE OPERATED AS INTENDED. THE VEHICLE WAS TAKEN TO VERA MOTORS (300 S UNIVERSITY DR., PEMBROKE PINES, FL 33025, (954) 362-9458) WHERE IT WAS DIAGNOSED THAT THE FUEL CONTROL MODULE NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED; HOWEVER, THE FAILURE RECURRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 115,000.
NHTSA complaint #11091693 — an unverified report by a vehicle owner.
TL* THE CONTACT OWNS A 2004 CHEVROLET EXPRESS. WHILE THE VEHICLE WAS STATIONARY, FUEL SPILLED ONTO THE GROUND. IT WAS DIAGNOSED THAT THE FILLER NECK WAS CORRODED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE. THE FAILURE MILEAGE WAS 148,000. UPDATED 04/11/2017
NHTSA complaint #10925238 — an unverified report by a vehicle owner.
TL* THE CONTACT OWNS A 2016 CHEVROLET EXPRESS. WHILE THE VEHICLE WAS BEING OPERATED AT 55 MPH, THE VEHICLE STALLED AND THERE WAS AN ABNORMAL FUEL ODOR. THE FAILURE OCCURRED WITHOUT WARNING. UPON INSPECTION, IT WAS NOTICED THAT THERE WAS A FUEL LEAK. THE VEHICLE WAS TOWED TO A TOW TRUCK LOT. THE VEHICLE WAS NOT DIAGNOSED NOR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 1,000. UPDATED 10/21/16*LJ THE CONSUMER STATED THE FUEL LINE SEPARATED, DUE TO A MISSING RETAINING CLIP. ALSO, TWO BRACKETS THAT WERE SUPPOSE TO ATTACH TO THE FUEL LINE WERE MISSING. UPDATED 10/25/16.
NHTSA complaint #10899303 — an unverified report by a vehicle owner.
TL* THE CONTACT OWNS A 1997 CHEVROLET EXPRESS. THE CONTACT STATED THAT A FUEL ODOR CAME FROM THE VEHICLE AND THE VEHICLE LEAKED FUEL ONTO THE GROUND. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS UNKNOWN. THE VIN WAS NOT AVAILABLE. UPDATED 04/22/16*LJ UPDATED 05/31/18
NHTSA complaint #10837621 — an unverified report by a vehicle owner.
VEHICLE WILL SHUT OFF WHILE DRIVING. NO WARNING SIGNS. WILL LOSE ALL POWER STEERING AND UNSTABLE CONTROL. WILL NOT START AFTER IT SHUTS DOWN FOR UP TO 24HRS. THIS VEHICLE ALSO HAS A HISTORY OF HARD/TROUBLE STARTING. WHEN IT TURNS OVER IS WILL GO INTO PROTECTION MODE "LOSS OF POWER". THIS PROBLEM STARTED AT 3,178 MILES AND HAS CONTINUED REGULARLY UP TO THE CURRENT 26, 050 MILES. JACK WILSON CHEVROLET OF SAINT AUGUSTINE HAS ATTEMPTED TO REPAIR THIS VEHICLE ELEVEN (11) TIMES SINCE THE 2ND DAY AFTER PURCHASE. AFTER OBTAINING ALL SERVICE RECORDS SINCE THIS VEHICLE WAS NEW THERE HAVE BEEN 24 ATTEMPTS AT REPAIRING THIS VEHICLE WITH NO SUCCESS. HERE IS A LIST OF REPAIRS PULLED FROM GM WORKBENCH SERVICE RECORDS. CONTINUAL CHECK ENGINE LIGHT. DEALER CANNOT FIND THE ISSUE. TO DATE - I SOLD THE VEHICLE BACK TO DEALER, THEY ARE SELLING, SO IT WILL BE BACK ON THE ROAD. LIST OF SERVICES - 3,178 MILES - ENGINE BLOCK PLUG REPLACEMENT 9,386 MILES - ROADSIDE SERVICE BATTERY TEST 9,400 MILES - ROADSIDE SERVICE TOWING 9,404 MILES - FUEL TANK FUEL PUMP MODULE REPLACEMENT 9,692 MILES - BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT 14,398 MILES - PASS. SIDE INSTRUMENT PANEL PERFORMANCE 14,434 MILES - RELAY REPLACEMENT 15,116 MILES - CONNECTOR RECONNECTION 15,857 MILES - IGNITION AND START SWITCH REPLACEMENT 16,090 MILES - ENGINE CONTROL MODULE REPLACEMENT 16,090 MILES - STARTER REPLACEMENT 12 DOCUMENTED "CHECK ENGINE LIGHT" PROBLEMS 6 DOCUMENTED TIMES THE VEHICLE STALLED ON THE HIGHWAY WHILE DRIVING 16 DOCUMENTED TIMES VEHICLE WOULD NOT START
NHTSA complaint #10809792 — an unverified report by a vehicle owner.