2002 Chevrolet Express 3500 problems
The Chevrolet Express (also known as the GMC Savana) is a series of full-size vans produced by General Motors since 1996. The successor to the Chevrolet G-series van, the Express is produced in passenger and cargo variants. Alongside the standard van body, the line is offered as a cutaway van chassis; the latter vehicle is a chassis cab variant developed for commercial-grade applications, including ambulances, buses, motorhomes, and small trucks.
In production for a single generation since 1995, over 2.5 million examples of the Express and the Savana have been produced. One of the longest-produced designs in American automotive history, the Express/Savana are rivaled only by the Jeep Wagoneer and Dodge Ram Van for longevity.
Since 1995, General Motors has assembled the Express and Savana at its Wentzville Assembly facility (Wentzville, Missouri). Also, since 2017, GM has sourced commercial cutaway-chassis production from Navistar through its Springfield Assembly Plant (Springfield, Ohio).
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Common 2002 Chevrolet Express 3500 problems
The Chevrolet Express 3500, a popular choice for commercial and industrial use, has been reported to have several common problems by its owners. These issues range from electrical and mechanical failures to safety recalls, affecting the overall performance and reliability of the vehicle.
- Fuel Level Sensor Failure:
The fuel level sensor in the Chevrolet Express 3500 has been reported to fail, causing inaccurate fuel gauge readings. This can lead to unexpected fuel shortages and potential stranding of the vehicle, as well as difficulty in determining the actual fuel level.
- Replace Fuel Filter Every 30,000 to Prevent Fuel System Issues:
To maintain the fuel system's optimal performance, it is recommended to replace the fuel filter every 30,000 miles. Failure to do so can result in clogged fuel filters, leading to reduced engine performance, stalling, and other fuel system issues.
- Brake Assembly Pressure Accumulator Cracking:
Certain Chevrolet Express 3500 models equipped with Bosch Hydro-Boost brake assemblies may experience cracking and separation of the hydro-boost assembly's pressure accumulator during normal operating conditions. This can lead to a loss of brake assist, prolonged stopping distances, and potential accidents.
- Wheel Bearing Assembly Retaining Nut Missing:
Some Chevrolet Express 3500 vans were built without a wheel bearing assembly retaining nut, which could lead to a possible bearing separation. This can cause the ABS system to be disabled, resulting in a grinding noise, decreased vehicle speed, and steering pulling in the direction of the affected brake assembly. This can increase the risk of a crash due to loss of vehicle control.
- Front Safety Belt Buckles Not Releasing After a Crash:
On certain vans with a gross vehicle weight of less than 8,500 pounds, during a crash sufficient to deploy the safety belt pretensioner, the front safety belt buckles may not release after a crash. This can result in an increased risk of personal injury.
- Courtesy Light Overheating:
Certain 2001 Chevrolet Express 3500 models equipped with Southern Comfort built running boards containing courtesy lights manufactured by American Technology Components, Inc. may experience overheating of the courtesy lights when the wiring harness is exposed to excessive moisture and road salt. This can lead to potential engine compartment fires.
- Power Steering Cooler Hose Separation:
Passenger vans equipped with a brake warning indicator may have a power steering cooler hose that can separate from the power brake booster fluid flow witch assembly. If this occurs, power steering fluid could flow onto hot engine parts, causing an engine compartment fire.
- Fuel Pump Failure:
The 1999 Chevrolet Express has been reported to have a high number of fuel pump failures, which can lead to stalling, difficulty starting, and reduced engine performance. The average cost to fix this issue is $3,000, with an average mileage of 25,000 miles at the time of failure.
- Ignition Module Harness Wire Cracking:
The ignition module harness in some Chevrolet Express models may have a wire that cracks, leading to intermittent or complete loss of engine power. This can cause the vehicle to stall or fail to start, increasing the risk of accidents and stranding the vehicle.
These common problems in the Chevrolet Express 3500 highlight the importance of regular maintenance and inspections to ensure the vehicle's safety, reliability, and performance. Addressing these issues promptly can help prevent more severe problems and extend the vehicle's lifespan.
How many miles does a Chevy Express 3500 last?
The 2021 Chevrolet Express lasts around 200,000 miles, with some average wheel noise and fuel pump issues reported.
What is the gas mileage for a 2002 Chevy Express van 3500?
Based on data from 7 vehicles, 293 fuel-ups and 70,770 miles of driving, the 2002 Chevrolet Express 3500 gets a combined Avg MPG of 11.18 with a 0.43 MPG margin of error.
How many miles per gallon does a Chevy Express 3500?
Fuel Economy
| City | 11 mpg |
|---|---|
| Highway | 16 mpg |
| Combined | 12 mpg |
Are Chevy Express vans reliable?
The Chevrolet Express 1500 Reliability Rating is 3.0 out of 5.0, which ranks it 9th out of 21 for commercial vans. The average annual repair cost is $963 which means it has poor ownership costs.
How many miles does a Chevy Express 3500 last?
The 2021 Chevrolet Express lasts around 200,000 miles, with some average wheel noise and fuel pump issues reported.
What is the gas mileage for a 2002 Chevy Express Van 3500?
Based on data from 7 vehicles, 293 fuel-ups and 70,770 miles of driving, the 2002 Chevrolet Express 3500 gets a combined Avg MPG of 11.18 with a 0.43 MPG margin of error.
Are Chevy Express vans reliable?
The Chevrolet Express 1500 Reliability Rating is 3.0 out of 5.0, which ranks it 9th out of 21 for commercial vans. The average annual repair cost is $963 which means it has poor ownership costs.
How many MPG does a Chevy Express 3500 get?
Fuel Economy
| City | 12 mpg |
|---|---|
| Highway | 16 mpg |
| Combined | 14 mpg |
2002 Chevrolet Express 3500 complaints
The NHTSA has received 0 complaints about various vehicle components related to the 2002 Chevrolet Express 3500.
You can leave your car complaint via the special form below.
2002 Chevrolet Express 3500 recalls
The National Highway Traffic Safety Administration (NHTSA) has issued 1 recalls for different components of the 2002 Chevrolet Express 3500.
- Manufacturer: HONEYWELL INTERNATIONAL, INC.
- Components: EQUIPMENT
- Summary: CERTAIN HONEYWELL FRAM RACING BRAND HP4 AND HP8 OIL FILTERS THAT WERE MANUFACTURED FROM MAY 25, 2006, THROUGH SEPTEMBER 14, 2007, AND SOLD FOR USE AS REPLACEMENT EQUIPMENT FOR VEHICLES LIST ABOVE. THE AFFECTED FILTERS ARE MARKED WITH A DATE CODE A61451 THROUGH A72571 SEQUENTIALLY. THE DATE CODE AND PART NUMBER APPEAR ON THE FILTER HOUSING. FRAM RACING HP4 AND HP8 OIL FILTERS NOT BEARING A DATE CODE IN THIS RANGE ARE NOT AFFECTED BY THIS RECALL. THE GASKET OF THE OIL FILTER BECOMES MORE PLIABLE UNDER HIGH TEMPERATURES AND PRESSURES.
- Consequence: THIS CONDITION MAY CAUSE INADEQUATE SEALING AND LOSS OF ENGINE OIL, POSSIBLY RESULTING IN A FIRE.
- Remedy: HONEYWELL WILL REPLACE THE AFFECTED OIL FILTERS FREE OF CHARGE. THE RECALL BEGAN DURING NOVEMBER 2007. OWNERS CAN CONTACT FRAM CUSTOMER SERVICE TOLL-FREE AT 1-800-890-2075.
Additional sources
More sources of information about 2002 Chevrolet Express 3500 problems:
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