2016 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 2016 Chevrolet Express problems
The Chevrolet Express 2016 has been reported to have several common problems based on complaints from owners. Here are some of the issues in detail:
- Electrical System Issues: The 2016 Chevrolet Express has been reported to have electrical system issues. Specifically, there is a recall for certain 2016-2018 Chevrolet Express vehicles equipped with a single, manual, rear climate control module (CCM). If the temperature is set to maximum heat or the mode knob is set to maximum floor vent and an electrical short occurs, components within the CCM may overheat. This can increase the risk of a fire, and GM will remove the electrical insulation from a wiring connector within the CCM to remove the fire risk, free of charge.
- Visibility Issues: Another recall for the 2016 Chevrolet Express is for certain 2016-2019 Chevrolet Express vehicles. One or both of the rear-quarter windows may be tempered glass instead of laminated glass. This means that these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 226, "Ejection Mitigation." GM will replace the tempered glass windows with laminated glass windows, as necessary, free of charge.
- Tail Light Wiring Damage: The tail light wiring in the 2016 Chevrolet Express can become damaged due to normal wear and tear from using the cargo space of the van. This can cause the rear lights to stop working. Replacing and protecting a new tailight harness should fix this issue, with the tail light harness costing about $30 and add another $3 for each bulb that you replace.
- Fuel Level Sensor Failure: The fuel level sensor in the 2016 Chevrolet Express may fail, causing the fuel tank to read the fuel level incorrectly. It is recommended that the whole fuel pump module be replaced, which can range from $600-$1000.
- Intake Manifold Gasket Leak: The intake manifold gasket in the 2016 Chevrolet Express may develop an external engine oil or coolant leak. In some cases, and internal coolant leak may occur also, causing the coolant to mix with engine oil. Running the engine with this internal leak can cause engine damage. Replacing the intake manifold gasket will correct this issue, which can cost around $500.
- Coolant Leak and Engine Overheating: This problem comes from the water pump, which can result in an engine overheating. To fix this, replace the water pump, which can run about $300-$550.
- Damaged Front Electrical Components: If excess water is used while cleaning the vehicle, various electrical components under the front carpet/rubber mat may become damaged. To avoid this issue, it is recommended not to hose down the rear cargo mat.
It is important to note that these issues are based on complaints from owners and may not be representative of all 2016 Chevrolet Express vehicles. Additionally, some of these issues may have been addressed by recalls or other manufacturer actions.
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.
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.
How many miles per gallon does a Chevy Express van get?
Based on data from 8 vehicles, 274 fuel-ups and 92,281 miles of driving, the 2021 Chevrolet Express 2500 gets a combined Avg MPG of 14.91 with a 0.21 MPG margin of error. Below you can see a distribution of the fuel-ups with 60 outliers (17.96%) removed.
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.
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.
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.
2016 Chevrolet Express complaints
The NHTSA has received 0 complaints about various vehicle components related to the 2016 Chevrolet Express.
You can leave your car complaint via the special form below.
2016 Chevrolet Express recalls
The National Highway Traffic Safety Administration (NHTSA) has issued 6 recalls for different components of the 2016 Chevrolet Express.
- Manufacturer: General Motors LLC
- Components: VISIBILITY:GLASS, SIDE/REAR
- Summary: General Motors LLC (GM) is recalling certain 2016-2019 Chevrolet Express and GMC Savana vehicles. One or both of the rear-quarter windows may be tempered glass instead of laminated glass. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 226, "Ejection Mitigation."
- Consequence: Tempered glass increases the risk of injury in the event of a side impact or rollover crash.
- Remedy: GM will notify owners, and dealers will replace the tempered glass windows with laminated glass windows, as necessary, free of charge. The recall began July 5, 2019. Owners may contact GM customer service at 1-586-596-1733. GM's number for this recall is N192218960.
- Manufacturer: General Motors LLC
- Components: ELECTRICAL SYSTEM
- Summary: General Motors LLC (GM) is recalling certain 2016-2018 Chevrolet Express and GMC Sierra vehicles equipped with a single, manual, rear climate control module (CCM). If the temperature is set to maximum heat or the mode knob is set to maximum floor vent and an electrical short occurs, components within the CCM may overheat.
- Consequence: If the CCM overheats, there is an increased risk of a fire in the vehicle's headliner.
- Remedy: GM will notify owners, and dealers will remove the electrical insulation from a wiring connector within the CCM to remove the fire risk, free of charge. The recall began November 6, 2018. Owners may contact Chevrolet customer service at 1-800-222-1020 or GMC customer service at 1-800-462-8782. GM's number for this recall is 18299.
- Manufacturer: General Motors LLC
- Components: VISIBILITY:POWER WINDOW DEVICES AND CONTROLS
- Summary: General Motors LLC (GM) is recalling certain 2014-2017 Chevrolet Express and GMC Savana vehicles equipped with power windows. Liquid may leak into the driver's power window switch and cause corrosion, resulting in high electrical resistance.
- Consequence: High electrical resistance can increase the risk of a fire.
- Remedy: GM will notify owners, and dealers will replace the driver side window switch, free of charge. The recall began August 10, 2018. Owners may contact Chevrolet customer service at 1-800-222-1020 or GMC customer service at 1-800-462-8782. GM's number for this recall is 18155.
- Manufacturer: General Motors LLC
- Components: EQUIPMENT
- Summary: General Motors LLC (GM) is recalling certain 2009-2014 Chevrolet Silverado HD and GMC Sierra HD, 2009 GMC Topkick 5000, 6000, 7000 and 8000 Series and Isuzu F Series, and 2009-2018 Chevrolet Express, and GMC Savana vehicles, equipped with certain Plastic-Handle Fire Extinguishers or Push Button 'Pindicator' Fire Extinguishers. These extinguishers may become clogged, preventing the extinguisher from discharging as expected or requiring excessive force to activate the extinguisher. Additionally, in certain models, the nozzle may detach from the valve assembly with enough force that it could cause injury and also render the product inoperable. For a full list of the affected fire extinguisher models visit: https://static.nhtsa.gov/odi/rcl/2017/RMISC-17E062-5427.pdf
- Consequence: In the event of a fire, if the fire extinguisher does not function properly, it can increase the risk of injury.
- Remedy: GM will notify owners, instructing them to contact Kidde to get a replacement fire extinguisher, free of charge. The recall began June 11, 2018. Owners may contact Chevrolet customer service at 1-800-222-1020, GMC customer service at 1-800-462-8782, and Isuzu customer service at 1-866-441-9638. GM's number for this recall is 18146.
- Manufacturer: General Motors LLC
- Components: VISIBILITY:REARVIEW MIRRORS/DEVICES
- Summary: General Motors LLC (GM) is recalling certain model year 2016-2017 Chevrolet Express manufactured September 25, 2015, to August 22, 2016, and 2016 GMC Savana cargo and cutaway vans manufactured January 28, 2016, to May 18, 2016. The affected vehicles were manufactured without an inside rearview mirror and with a right-hand convex exterior review mirror. These vehicles are required to have either an inside rearview mirror or both left and right-hand flat exterior rearview mirrors. Thus, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 111, "Rearview Mirrors."
- Consequence: If the driver does not have a clear unobstructed view to the back of the vehicle, it can increase the risk of a crash.
- Remedy: GM will notify owners, and dealers will instal a right-hand flat rearview mirror, free of charge. The recall began on November 8, 2016. Owners may contact Chevrolet customer service at 1-800-222-1020, or GMC customer service at 1-800-462-8782. GM's number for this recall is 16036.
- Manufacturer: General Motors LLC
- Components: TIRES:PRESSURE MONITORING AND REGULATING SYSTEMS
- Summary: General Motors LLC (GM) is recalling certain model year 2014-2016 Chevrolet Express and GMC Savana incomplete vehicles equipped with a 159 inch wheel base manufactured August 2, 2013, to January 30, 2016. The affected vehicles were shipped to final stage manufacturers without a tire pressure monitoring system (TPMS). As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 138, "Tire Pressure Monitoring Systems."
- Consequence: Without a TPMS, the driver would not be alerted if one or more tires became under inflated. Driving with under inflated tires increases the risk of a crash.
- Remedy: GM will notify owners, and dealers will install the hardware and software necessary to equip the vehicles with a TPMS, free of charge. The recall began on May 25, 2016. Owners may contact Chevrolet customer service at 1-800-222-1020, or GMC customer service at 1-800-462-8782. GM's number for this recall is 15819.
Negative 2016 Chevrolet Express car reviews
Positive 2016 Chevrolet Express car reviews
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This is actually my second Express van and I must say, I'm really happy with it. I have the 12 passenger van which is just the right size for me. The 08 model has been given many upgrades over older models, which is great. The seats can easily be removed, and you can almost put your whole house in there! My previous Express van was trouble free and I'm happy to say that my 08 came with no defects, so it's off to a good start.
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It's great to hear that you find the vehicle comfortable to drive with excellent handling. The engine and transmission are very smooth and powerful, and it's impressive that it's so efficient with up to 19 mpg on the highway and averaging over 16 mpg for all driving combined. The cruise control is also very efficient. It's good to know that this vehicle is much more comfortable to drive and handle than the Honda Pilot that it replaced.
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The van has been awesome for a family. Ours was a Waldoch conversion. The ride was great and super easy for long drives. Although we did experience some mechanical issues, such as the transmission going out at 105,000 miles and the airbag and engine lights being issues at 37,000 miles, we still enjoyed our time with it. Unfortunately, there was no warranty available.
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We were in search of a vehicle that could tow a trailer and accommodate 7 passengers. Unfortunately, most SUVs we looked at had a back seat that was difficult to access, similar to a 2-door car. On the other hand, small vans were not suitable for towing a trailer. After much consideration, we found that conversion vans were the perfect fit for our needs. It's an absolute pleasure to drive and tow with this vehicle, as it feels like the trailer isn't even there. The van has a lot of power, even on hills, and provides a smooth ride while handling like a smaller vehicle. Although we test drove the Ford, we found it lacking as it felt like we were driving a truck and we couldn't get the 4th door. However, the gas mileage is not as bad as we initially feared, as we get 13mpg with the trailer, 19 on the open road, and 14/15 every day.
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Buying a 2004 Chevy Express 3500 Extended Van was an easy decision for us. We needed a vehicle that could accommodate 11 people and our belongings, and we found the perfect fit. Despite its size, the Express 3500 is surprisingly fuel-efficient, consuming about the same amount of gas as two compact cars. We love the adventurous styling and all the interior appointments, including the AM/FM/CD changer Sound Sys, cruise control, All Power, 6way pwr. driver seat, factory tint, OnStar, and more. Our family is extremely satisfied with our new 2004 Express 3500, and we have no complaints whatsoever!
Additional sources
More sources of information about 2016 Chevrolet Express problems:
2016 Chevrolet Express 2500 Cargo Problems | Kelley Blue Book
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Other years of Chevrolet Express
Are you having problems with your 2016 Chevrolet Express?
Tobin Legros 2025-11-29
I bought the van slightly used instead of a 2008 Dodge Sprinter. I saved over $25000, which can pay for years of fuel, and I am happy to support an American-made product. My family and I are thrilled with the van! The fuel economy is better than expected (approximately 16.5 MPG on the highway). The only downside is the quality and fit of the plastic trim inside the vehicle.
Derick Cruickshank 2025-11-29
I really appreciate the design of the van, especially the exterior look and the rear doors with hinges that are designed to maximize access and storage. However, I am sorry to hear that you have had some issues with reliability. It sounds like you have had to replace the fuel pump ($600), the water pump, and one of the side windows fell out ($1000). I understand that the mechanic at the Kingman AZ dealership told you that there is a design flaw in the fuel pump which manifests itself primarily in higher elevation, hotter climates, and that Chevy knows about it but won't replace them. It must have been frustrating to have to make all these repairs while the vehicle had less than 75,000 miles.
Jed Marvin 2025-11-11
I love my 2006 Chevy Express! My only issue is that it's quite challenging to find a parking spot for it. It's longer and wider than any of my other cars, including my Suburbans.
Titus Wilkinson 2025-10-16
I have experience driving several different vans of this model, ranging from '06 to '09. The engine provides excellent power, and the AWD system really helps with road grip. However, the gas mileage could be improved, as the best I've ever gotten is 17mpg (on 87 octane gas). I did find the traction control system to be a bit unnerving, as it shuts off all power for several seconds if you lose traction, which can be concerning when pulling out onto a busy intersection. On the other hand, I appreciate some of the features, such as the on-board tire pressure monitors and the oil life percentage. Overall, I think it's a good van. The only issue I've had was an oil filter gasket leak, which was likely due to an installation fault by the garage.
Kelley Howe 2024-09-16
While the engine and transmission of these vehicles are superior to those of Fords, the rest of the vehicle falls short. The old 1975-1992 Econoline has more room, feels better, drives better, handles better, and has a more solid body. The interior of the Express is uncomfortable and made of hard plastic that creaks and feels like it might break. The front seating is cramped and less roomy than Ford. The ride is not very smooth and can be a bit rough. The sliding door rattles and shakes when closed gently. All doors, controls, seats, and dash feel cheap compared to Ford. However, we understand that everyone has different preferences and priorities when it comes to choosing a vehicle.