1996 Chevrolet Express 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 1996 Chevrolet Express problems
The Chevrolet Express 1996 has several common problems based on complaints from owners of this car.
One of the most reported problems is the fuel pump failure. This issue affects the 1999 model year the most, but it can also occur in the 1996 model. The fuel pump failure can cause the engine to stall or not start at all. The average cost to fix this issue is around $3,000, and it typically occurs at an average mileage of 25,000 miles.
Another common problem is related to the brake system. Certain trucks, sport utility vehicles, and vans equipped with Bosch Hydro-Boost brake assemblies may have a hydraulic brake booster pressure accumulator that can crack and separate from the Hydro-Boost assembly during normal operating conditions. This issue can cause a loss of vehicle control, increasing the risk of a crash. The recall affects certain vans with a gross vehicle weight of less than 8,500 pounds. The manufacturer has reported that owner notification began Nov. 13, 2002. Owners should contact Chevrolet at 1-800-222-1020 or GMC at 1-800-462-8782.
The front safety belt buckles may not release after a crash, or may cause the buckle to unlatch in a crash, resulting in an increased risk of personal injury. This issue affects certain vans with a gross vehicle weight of less than 8,500 pounds. The manufacturer has reported that owner notification is expected to begin during April 2003. Owners should contact Chevrolet at 1-800-222-1020, or GMC at 1-800-462-8782.
The intake manifold gasket may develop an external engine oil or coolant leak. In some cases, and internal coolant leak may occur also which causes the coolant to mix with engine oil. Running the engine with this internal leak can cause engine damage. In this case, replacing the intake manifold gasket will correct this issue. This repair can cost around $500.
The coolant leak comes from the water pump, which can result in an engine overheating. To fix this, replace the water pump. This repair can run about $300-$550.
The tail light wiring can be damaged due to normal wear and tear from using the cargo space of the van. This damage can cause the rear lights to stop working. Replacing and protecting a new tailight harness shout do the trick. The tail light harness costs about $30 and add another $3 for each bulb that you replace.
The fuel level sensor may fail, causing the fuel tank to read the fuel level incorrectly. It is recommended that the whole fuel pump module be replaced. Replacing the entire fuel pump can range from $600-$1000.
The electrical components under the front carpet/rubber mat may become damaged if excess water is used. Consider an extended warranty to cover repair costs.
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 long do Chevy Express engines last?
If you have a 4.3 V6 250,000 miles would be good. If you have a 4.8L, 5.3L or 6.0L V8 all are LS based engines. Those engines if cared for properly 300,000 is not uncommon. If you drive it like you stole it all the time you will be lucky to make 150,000 miles.
How many miles does a Chevy Express get?
Gas Mileage 7/10 – Fuel economy is okay at up to 20 MPG, offering 620 miles of range out of the 31 gallon tank. Gas costs are similar to other vans, at $369 per month. Value 8/10 – The 2019 Chevrolet Express is cheaper than a lot of other full size vans with reasonable depreciation rates, making it an attractive value.
What is the recall on the Chevy Express van?
Recall # N202325160 Date: 03/18/2021 Recall: General Motors, LLC is recalling certain 2021 Chevrolet Express and GMC Savana vehicles equipped with 6.6L gasoline engines. The positive battery cable terminals may contact a fuse block assembly attachment post and cause an electrical short circuit.
Is the Chevrolet Express a reliable van?
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 long do Chevy Express engines last?
If you have a 4.3 V6 250,000 miles would be good. If you have a 4.8L, 5.3L or 6.0L V8 all are LS based engines. Those engines if cared for properly 300,000 is not uncommon. If you drive it like you stole it all the time you will be lucky to make 150,000 miles.
How many miles does a Chevy Express get?
Gas Mileage 7/10 – Fuel economy is okay at up to 20 MPG, offering 620 miles of range out of the 31 gallon tank. Gas costs are similar to other vans, at $369 per month. Value 8/10 – The 2019 Chevrolet Express is cheaper than a lot of other full size vans with reasonable depreciation rates, making it an attractive value.
What engine does a Chevy Express use?
V6 engine
The 2021 Chevrolet Express includes a more-than-adequate 4.3-liter, V6 engine that easily achieves 276 horsepower and 298 pound-foot of torque with an eight-speed automatic transmission.
1996 Chevrolet Express car problems categorized by type of issue
After analyzing all complaints sent to the NHTSA and researching popular Chevrolet Express problems, we found that the most common problems with these 2023 model year vehicles are:
- Engine and engine cooling problems
- Electrical system problems
- Fuel system problems
- Gasoline problems
- Equipment problems
The graph below shows statistics for all 1996 Chevrolet Express vehicle components and the number of complaints received.
1996 Chevrolet Express complaints
The NHTSA has received 15 complaints about various vehicle components related to the 1996 Chevrolet Express.
POWER TRAIN PROBLEM
- Date Of Incident: 2003-01-07
- Fire: 1
- VIN: 1GBFG15R3T1
- Components: POWER TRAIN
- Summary: WE WERE ON OUR WAY TO FLORIDA WHEN WE STARTED SMELLING SOMETHING. WE PULLED TO THE SIDE OF THE ROAD AND TURNED OFF THE IGNITION. WE OPENED THE HOOD AT THAT TIME NOTICED FLAMES COMING FROM UNDER NEATH THE DRIVERS SIDE. WE BARELY HAD ENOUGH TIME TO GET OUT BEFORE IT WAS TOTALLY ENGULFED WITH FLAMES. AT THE TIME WE WERE TOWING AN ENCLOSED TRAILER WITH A 2003 HONDA GOLDWING. NOTHING PRIOR TO THIS INCIDENCE GAVE US ANY CLUE THAT THE VAN WAS ON FIRE. WE LOST ALL OUR POSSESSIONS IN THE VAN AND TRAILER. IT WAS ALL 100% DESTROYED. UNKNOWN CAUSE. WE HAD NOTICED THAT WE WERE USING MORE FUEL. AND WHEN WE PULLED THE VAN OVER TO THE SIDE OF THE ROAD WE NOTICED TRANSMISSION FLUID ON THE GROUND FROM WHERE WE PULLED OVER UNTIL WE GOT STOPPED.
ENGINE AND ENGINE COOLING PROBLEM
- Date Of Incident: 2002-08-22
- VIN: 1GBFG15ROT1
- Components: ENGINE AND ENGINE COOLING
- Summary: AFTER APPOINTMENT WAS MADE, AND UPON ARRIVAL, DEALERSHIP REFUSED TO DO RECALL OOV110000 REPAIRS.*AK *SLC
EQUIPMENT PROBLEM
- Date Of Incident: 2001-08-09
- VIN: 1GBFG15R7T1
- Components: EQUIPMENT
- Summary: THE STEEL CABLE SYSTEM SECURING THE SPARE TIRE RUSTED THROUGHAND SEVERED RELEASING THE SPARE TIRE TO FALL FREELY FROM UNDER THE VAN TO THE ROAD BELOW. AT THE SLOW SPEED I WAS TRAVELING I INCURRED NO LOSS OF CONTROL OR DANGER TO OTHER MOTORISTS, HOWEVER IF I WAS TRAVELING AT HIGHWAY SPEEDS THIS FAILURE WOULD HAVE RESULTED IN A 65MPH MISSLE GOING DOWN THE ROAD. CALLS TO THE MANUFACTURER RESULTED IN NO ACTION. I AM IN POSSESSION OF ALL FAILED PARTS. THANK YOU
ELECTRICAL SYSTEM PROBLEM
- Date Of Incident: 2001-09-02
- Fire: 1
- VIN: 1GBFG15M8T1
- Components: ELECTRICAL SYSTEM
- Summary: THE HORN RELAY WAS SMOKING AND MELTED THE RELAY PANEL IT WAS MOUNTED TO. MORA FIRE DEPARTMENT WAS CALLED. THEY DISCONNECTED THE BATTERY. THE RELAY AND FUSE HAVE BEEN REMOVED AS A TEMPORARY FIX UNTIL A DEALER CAN INSTALL A NEW RELAY PANEL AND FIND THE PROBLEM. THIS GAVE NO WARNING SIGNS. THE VAN HAD BEEN TURNED OFF SINCE 12:20 PM. THE HORN WAS SILENT AT 2:00 PM WHEN MY WIFE BROUGHT SOMETHING IN FROM THE REAR COMPARTMENT OF THE VAN. AT AROUND 3:10 PM MY WIFE NOTICED THE HORN SOUNDING AND WENT TO CHECK IT OUT. SHE NOTICED SMOKE FROM DRIVER'S SIDE COMING OUT FROM UNDER THE HOOD. SHE OPENED THE HOOD AND NOTICED THE BATTERY WAS ALSO STARTING TO SMOKE. SHE DIALED THE SHERIFF'S OFFICE DISPATCHER TO GET THE FIRE DEPARTMENT ON THE SCENE. THE FIRE DEPARTMENT DISCONNECTED THE BATTERY AND STAYED AFTERWARDS TO ENSURE NO HOT EMBERS EXISTED. *AK ----DIMS 11 IVOQ ENTRY POSTED AFTER 12/12/02 CUT-OVER TO ARTEMIS-----751677.
STEERING PROBLEM
- Date Of Incident: 1997-09-01
- VIN: 1GBFG15R6T1
- Components: STEERING
- Summary: WHEN PARKED STEERING WILL NOT TURN. STEERING GEAR BOX & PUMP REPLACED WITH NO EFECT.
ENGINE AND ENGINE COOLING,FUEL SYSTEM, GASOLINE PROBLEM
- Date Of Incident: 2024-11-24
- VIN: 1GBFG15MXT1
- Components: ENGINE AND ENGINE COOLING,FUEL SYSTEM, GASOLINE
- Summary: CONSUMER CONTACTED DEALER IN REFERENCE TO RECALL 00V110000/MANUFACTURER'S RECALL 00031 CONCERNING FUEL ODOR/LEAKAGE. DEALER CORRECTED RECALL PROBLEM. CONSUMER BELIEVED RECALL PROBLEM HAS CAUSED ADDITIONAL PROBLEMS IN FUEL SYSTEM. FUEL SYSTEM WAS CONTAMINATED, AND FUEL PUMP/ FILLER NEEDED TO BE REPLACED. PLEASE PROVIDE ANY FURTHER DETAILS.*AK
FUEL SYSTEM, GASOLINE PROBLEM
- Date Of Incident: 2024-11-24
- VIN: 1GCFG25M5T1
- Components: FUEL SYSTEM, GASOLINE
- Summary: WHILE DRIVING VEHICLE HAD STALLED OUT. LOST STEERING AND BRAKING POWER. TOWED TO DEALERSHIP. INFORMED BY MECHANIC THAT FUEL PUMP HAD FAILED AND NEEDED TO BE REPLACED. THIS HAS HAPPENED 3 TIMES ALREADY.*AK THE DEALER SAID THERE WAS NO RECALL ON THE FUEL PUMP WHICH WAS FAILING NUMEROUS TIMES. *YH
SERVICE BRAKES, HYDRAULIC PROBLEM
- Date Of Incident: 2024-11-24
- VIN: 1GNFG15R7T1
- Components: SERVICE BRAKES, HYDRAULIC
- Summary: DIMINISHED BRAKING ABILITY,DIAGNOSED AS FAULTY ANTI-LOCK SYSTEM. *AK
STEERING PROBLEM
- Date Of Incident: 2000-10-31
- VIN: 1GBFG15MXT1
- Components: STEERING
- Summary: AFTER MAKING A U TURN, THE POWER STEERING ASSIST WAS LOST. THE POWER STEERING PUMP SHAFT HAD BROKEN MAKING THE VEHICLE NEARLY IMPOSSIBLE TO CONTROL. COULD THIS BE THE PROBLEM OF NHTSA CAMPAIGN #: 96V187000?
AIR BAGS PROBLEM
- Date Of Incident: 2000-01-12
- Crash: 1
- Components: AIR BAGS
- Summary: WHEN THE VAN WAS INVOLVED IN A PRETTY SEVERE FRONTAL CRASH, PASSENGER'S SIDE AIR BAG DID DEPLOY, BUT THE DRIVER'S SIDE DID NOT. VAN WAS TRAVELING ABOUT 5 MPH WHEN THIS HAPPENED. FRONTAL DAMAGE TOTALLED OVER $7,000 DOLLARS. THE VAN IS BEING REPAIRED. PLEASE PROVIDE ANY FURTHER INFORMATION. *AK
ENGINE AND ENGINE COOLING,ELECTRICAL SYSTEM PROBLEM
- Date Of Incident: 1999-03-20
- VIN: 1GBFG15R1T1
- Components: ENGINE AND ENGINE COOLING,ELECTRICAL SYSTEM
- Summary: ENGINE RUNS RUFF WITH NO POWER. SOUNDS LIKE ENGINE IS DIESELING. BLACK SMOKE COMES OUT OF EXHAUST, SOMTIMES BACKFIRES. ECM NEVER SETS TROUBLE CODE. EVENTUALLY THE ECM SET TROUBLE CODE FOR RIGHT CAT COMMING APART. THE FOURTH (MOST RESENT) BOTH CATS CAME APART. *AK
VISIBILITY,EQUIPMENT PROBLEM
- Date Of Incident: 1997-12-30
- VIN: 1GBFG15R7T1
- Components: VISIBILITY,EQUIPMENT
- Summary: NO SUMMARY
ELECTRICAL SYSTEM PROBLEM
- Date Of Incident: 1999-01-05
- Fire: 1
- VIN: 1GBFG15R7T1
- Components: ELECTRICAL SYSTEM
- Summary: VAN TOTALLY DESTROYED ,HAD BEEN SITTING FOR OVER 2 HOURS BEFORE IT DECIDED TO CATCH FIRE HAD TROUBLE WITH KEYLESS REMOTE PRIOR TO CATCHING FIRE REMOTE WOULD NOT UNLOCK DOORS FIRE STARTED UNDER NEATH PASS. SIDE DASHBOARD IN WHAT I WAS TOLD THE AREA WHERE THE COMPUTER IS
FUEL SYSTEM, GASOLINE PROBLEM
- Date Of Incident: 1998-08-07
- VIN: 1GBFG15M1T1
- Components: FUEL SYSTEM, GASOLINE
- Summary: VEHICLE'S FUEL TANK WAS FILLED ON THE MORINING OF 8/6/98 AND DRIVEN 33 MILES. IT WAS PARKED IN THE DRIVEWAY WITH THE NOSE DOWN ON A 30 DEGREE GRADE. ON THE AFTERNOON OF 8/7/98 AS WE WERE LEAVING ON VACATION I SMELLED GASOLINE WHILE GETTING INTO THE VAN. I LOOKED UNDERNEATH TO FIND FUEL DRAINING FROM OUT UNDERNEATH THE GAS TANK PLASTIC SHIELD ONTO THE DRIVEWAY. IT WAS DETERMINED AT THE DEALERSHIP THAT GAS WAS GOING THROUGH THE VENT PIPE, TO THE CHARCOAL CANISTER AND THEN OUT OF THE CANISTER INTO THE PLASTIC SHIELD AROUND THE TANK. IT WAS ALSO FOUND THAT ONE OF THE TOP SEALS ON THE TANK WAS ALSO LEAKING. MINE WAS THE 3RD EXPRESS VAN AT THE DEALERSHIP WITH A SIMILAR PROBLEM. WITH REPEATED DISCUSSIONS WITH THE FACTORY REP, I WAS TOLD I WOULD HAVE TO PAY FOR THESE SAFETY RELATED DEFECTS AND PARTS OF THE EXACT DESIGN THAT FAILED WERE REINSTALLED. THERE IS AN INHERENT DEFECT IN THIS DESIGN. WHEN THE TANK IS FILLED COOL, AND THE VEHICLE SITS OR IS DRIVEN WITH THE NOSE DOWN AND THE TEMPERATURE INCREASES, GASOLINE IS FORCED THROUGHT THE VENT PIPE, TO THE CHARCOAL CANISTER, THEN OUT ONTO THE GROUND. I WAS JUST LUCKY I NOTICED THIS PRIOR TO STARTING MY VAN. IT COULD HAVE BLOWN UP, ESPECIALLY WITH THE HEAT AND LEAVING IT SIT TO COOL DOWN SO MY NEWBORN WOULDNT HAVE TO GET INTO THE HOT VEHICLE. I WAS VERY UPSET WITH THIS SITUATION AND HAVE NOT BEEN SATISFIED WITH A RESPONSE, OR LACK THEREOF FROM CHEVROLET. I ALSO SAW A SIMILAR VEHICLE AS MINE SITTING BY THE ROADWAY THE OTHER DAY WITH FLAMES COMING OUT FROM UNDERNEATH THE VAN. PLEASE HELP MYSELF AND OTHERS BEFORE SOMEONE GETS HURT.
SERVICE BRAKES, HYDRAULIC PROBLEM
- Date Of Incident: 2024-11-24
- VIN: 1GBFG15MOT1
- Components: SERVICE BRAKES, HYDRAULIC
- Summary: BRAKE PEDAL MOVES TO 2-3 INCHES BEFORE IT WILL BEGIN TO BRAKE, AND PEDAL TRAVELS TOO FAR DOWN.THIS DEFECT CAUSES INCREASED REACTION TIME. DEALER AND MANUFACTURER CLAIM IT WAS DESIGNED LIKE THAT. *AK
1996 Chevrolet Express recalls
The National Highway Traffic Safety Administration (NHTSA) has issued 3 recalls for different components of the 1996 Chevrolet Express.
- Manufacturer: SABERSPORT
- Components: EXTERIOR LIGHTING
- Summary: SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
- Consequence: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
- Remedy: SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON MAY 11, 2009. OWNERS MAY CONTACT SABERSPORT AT 1-909-598-7589.
- Manufacturer: GENERAL MOTORS CORP.
- Components: FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS
- Summary: PASSENGER VANS. THESE VANS EXPERIENCE FUEL ODORS OR LEAKAGE.
- Consequence: FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A FIRE.
- Remedy: DEALERS WILL INSTALL A REVISED EVAPORATIVE EMISSION PIPE ASSEMBLY.
- Manufacturer: GENERAL MOTORS CORP.
- Components: SUSPENSION:REAR:SPRINGS:LEAF SPRING ASSEMBLY:U-BOLT, LEAF SPRING TO AXLE
- Summary: ONE OF THE FOUR REAR AXLE U-BOLTS CAN BREAK. THIS CAN POTENTIALLY LEAD TO THE SPRING LIFTING FROM THE AXLE UNDER CERTAIN REBOUND, BRAKING OR CORNERING MANEUVERS.
- Consequence: THIS CONDITION COULD RESULT IN SUDDEN LOSS OF VEHICLE CONTROL INCREASING THE POTENTIAL FOR A VEHICLE ACCIDENT.
- Remedy: DEALERS WILL REPLACE THE FOUR REAR AXLE U-BOLTS ON THE AFFECTED VEHICLES.
Negative 1996 Chevrolet Express car reviews
Additional sources
More sources of information about 1996 Chevrolet Express problems:
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Other years of Chevrolet Express
Are you having problems with your 1996 Chevrolet Express?
Irwin Brakus 2024-09-26
Hi there! I see that you've recently purchased a vehicle to pull your camping trailer. That's great! It's wonderful to hear that after 7 years, your vehicle is still running smoothly and reliably. However, I understand that you may have some concerns about the interior fit and finish. It seems that the plastic doesn't fit cleanly and the outside mirrors vibrate. I hope that these issues don't detract too much from your overall enjoyment of your vehicle. Let me know if there's anything I can do to help!
Nasir Kovacek 2024-06-27
I have a Mark III conversion van, so the interior is better than standard. While it's a good road warrior, I've had a few issues with it such as the ABS going out at 48k, the A/C at 25k, and a drive shaft leaking oil at 27k. The brakes are inadequate for such a large vehicle. At 59k, some bits and pieces of trim are departing or breaking, and I share the concern about vibrating rearview mirrors. The side door is also very flimsy. However, I am convinced that Chevy could build a better van if they tried. Now that my kids are bigger, our next car will be a Subaru, which I expect to last forever.
Mose Schulist 2024-06-14
Hello! We've had our Chevy G1500 conversion van for 16 months now. When we bought it, it only had 62000 miles on it, but now it has 76000 miles. Unfortunately, we've had to spend some money on repairs in the past 16 months. We've had to replace the brakes twice, which cost us $600, and we also had to spend $1700 on a new transmission, $700 on the A/C (condenser), and $200 on a water pump. All in all, we've spent $3200 on repairs so far, and we're worried that there might be more to come.
Jaren Erdman 2024-04-08
Hi there! I wanted to share my experience with my van. I bought it used and unfortunately, at 50,000 miles, the fuel pump went bad. I've had some trouble with the air conditioning too, and have spent over $1000.00 fixing it. I was hoping for better performance from a GM product, but unfortunately, I've had some issues. Additionally, I've noticed that the fit and finish could be improved, as the outside rear view mirrors vibrate excessively. Thanks for listening!