1996 Chevrolet G20 problems

General information about Chevrolet-G20
Overview of popular issues
Analysis of common problems
Сomplaints list
Recalls list

The Chevrolet Van or Chevy Van (also known as the Chevrolet/GMC G-series vans and GMC Vandura) is a range of vans that was manufactured by General Motors from the 1964 to 1996 model years. Introduced as the successor for the rear-engine Corvair Corvan/Greenbrier, the model line also replaced the panel van configuration of the Chevrolet Suburban. The vehicle was sold both in passenger van and cargo van configurations as well as a cutaway van chassis that served as the basis for a variety of custom applications.

Produced across three generations (1964–66, 1967–70, and 1970–96), the model line was sold under a wide variety of model names under both the Chevrolet and GMC brands. The first two generations were forward control vehicles (with the engine placed between the seats); the third generation adopted a configuration placing the engine forward of the driver. The second and third generations shared powertrain commonality with the C/K pickup truck model line.

After the 1996 model year, GM retired the G-Series vans, replacing them with the GMT600-platform Chevrolet Express and GMC Savana.

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Common 1996 Chevrolet G20 problems

Based on complaints from owners of the Chevrolet G20 1996, several common problems have been reported. Here is a detailed list of these issues:

Steering Shaft Knock or Clunking Noise: Many drivers have reported hearing a knock or clunking noise coming from the steering shaft of the Chevrolet G20 1996. This issue can be disruptive and may indicate underlying problems with the steering mechanism, potentially affecting the vehicle's handling and safety.
Service Stability Message Due to Failed Steering Wheel Position Sensor: Owners have experienced a service stability message in their Chevrolet G20 1996, which could be attributed to a failed steering wheel position sensor. This sensor failure may lead to intermittent errors or persistent warnings, impacting the overall stability and control of the vehicle.
Failed 4WD Transfer Case Encoder Motor Position Sensors or Selector Switches: Another common issue reported with the Chevrolet G20 1996 is the failure of the 4WD transfer case encoder motor position sensors or selector switches. This malfunction can affect the vehicle's ability to engage or disengage the 4WD system properly, potentially compromising its off-road capabilities.
Failed HVAC Temperature or Delivery Mode Door Actuators: Owners have encountered problems with the HVAC system in the Chevrolet G20 1996, specifically related to failed temperature or delivery mode door actuators. This issue can result in inconsistent heating or cooling inside the vehicle, leading to discomfort for passengers.
Failed Fuel Level Sensors: The Chevrolet G20 1996 has also been known to experience issues with failed fuel level sensors. Malfunctioning fuel level sensors can provide inaccurate readings of the fuel level in the tank, leading to uncertainties for the driver regarding fuel consumption and range.
Windshield Wiper Motor Component Failure: Owners have reported intermittent failures of the windshield wiper motor in Chevrolet G20 models manufactured between 1990 and 1999. This issue can result in the wipers not working, running continuously, or operating only at one speed setting, affecting visibility during adverse weather conditions.
Coolant Leaks or Oil Leaks From Intake Manifold Gaskets: Another common problem with the Chevrolet G20 1996 is coolant leaks or oil leaks from the intake manifold gaskets. These leaks can lead to engine overheating, loss of coolant or oil, and potential engine damage if not addressed promptly.

These issues highlight some of the common problems that owners of the Chevrolet G20 1996 have faced. Addressing these concerns promptly through proper maintenance and repairs is crucial to ensure the vehicle's optimal performance and safety on the road.

What is the gas mileage on a Chevy G20?

The 1992 G-Series G20 gets 17 MPG overall, with 15 MPG in the city and 20 MPG on the highway.

Is a Chevy G20 van a 3 4 ton?

An addition for 1967 was the G20 heavy-duty 3/4-ton version. The G-20 featured heavier suspension, a 12-bolt rear axle, and increased hauling capability with wheels having a 6-lug bolt pattern. The G20 model was available only on the 108-inch wheelbase version.

What is the difference between a G20 and a G30 Chevy van?

G20-25 is a 3/4 ton with 5 lug wheels. G30-35 is the heavy duty style van. These vans can come with 6 to 8 lug set ups and the heavier duty floating rears. box style vans can even come with dual wheels.....

What is the mpg on a 1995 Chevy Van G20?

Based on data from 9 vehicles, 275 fuel-ups and 72,761 miles of driving, the 1995 Chevrolet G20 gets a combined Avg MPG of 11.82 with a 0.24 MPG margin of error. Below you can see a distribution of the fuel-ups with 42 outliers (13.25%) removed.

What is the gas mileage on a Chevy G20?

The 1992 G-Series G20 gets 17 MPG overall, with 15 MPG in the city and 20 MPG on the highway.

Is a Chevy G20 van a 3 4 ton?

What is the mpg on a 1995 Chevy Van G20?

What is the difference between a G20 and a G30 Chevy van?

1996 Chevrolet G20 car problems categorized by type of issue

After analyzing all complaints sent to the NHTSA and researching popular Chevrolet G20 problems, we found that the most common problems with these 2023 model year vehicles are:

Tires problems
Visibility problems
Suspension problems
Structure problems
Air bags problems

The graph below shows statistics for all 1996 Chevrolet G20 vehicle components and the number of complaints received.

1996 Chevrolet G20 complaints

The NHTSA has received 9 complaints about various vehicle components related to the 1996 Chevrolet G20.

2000-09-06

TIRES PROBLEM

Date Of Incident: 1999-06-22
VIN: 1GBEG25K7RF
Components: TIRES
Summary: 4 FIRESTONE ATX LT225/75R15 INSTALLED AS A REPLACEMENT ON 02/12/1998, MILEAGE ON CHEV G20 CONVERSION VAN WAS 46327. BLOWOUT ON 06/22/1999, MILEAGE 69918. PURCHASED 1 NEW FIRESTONE ATX TIRE. BECAUSE OF ANOTHER BLOWOUT ON 03/02/2000, 2 NEW FIRESTONE ATX TIRES WERE PURCHASES, HOWEVER, RECEIPT NOW SHOWS P225/75R15. ON 04/21/2000 ANOTHER BLOWOUT OCCCURRE AND WE PURCHASED 1 MORE FIRESTONE ATX TIRE. RECEIPT SHOWS P225/75/R15. IN TOTAL, WE HAVE HAD 3 BLOWOUTS ON FIRESTONE ATX TIRES, ALL BLOWOUTS WERE ON THE SAME VAN. TIRES AFFECTED WERE IN DIFFERENT LOCATIONSON THE VAN. 2 BLOWOUTS OCCURRED GOING 70 MPH; ONE OCCURRED AT 11 PM AT NIGHT, THE OTHER 10 AM IN THE MORNING. THE THIRD OCCURRED ON CITY BY-PASS ROAD ABOUT 5 PM. VAN HAS HAD REGULAR MAINTENANCE AT CHEVY DEALER; I HAVE RECEIPTS SHOWING REGULAR TIRE CHECKS AND ROTATIONS. WE HAVE REMOVED THE FIRESTONE ATX TIRES FROM OUR VAN AND HAVE REPLACED THEM WITH COMPETITOR TIRES. I HAVE RETAINED THE FIRESTONE TIRES--THEY HAVE LESS THAN 4,000 MILES ON THEM...THANKS FOR YOUR HELP, AND "LISTENING". *AK( DOT NUMBER: UNKNOWN TIRE SIZE: P255/75R15 )

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2000-09-06

TIRES PROBLEM

Date Of Incident: 1999-06-22
VIN: 1GBEG25K7RF
Components: TIRES
Summary: 4 FIRESTONE ATX LT225/75R15 INSTALLED AS A REPLACEMENT ON 02/12/1998, MILEAGE ON CHEV G20 CONVERSION VAN WAS 46327. BLOWOUT ON 06/22/1999, MILEAGE 69918. PURCHASED 1 NEW FIRESTONE ATX TIRE. BECAUSE OF ANOTHER BLOWOUT ON 03/02/2000, 2 NEW FIRESTONE ATX TIRES WERE PURCHASES, HOWEVER, RECEIPT NOW SHOWS P225/75R15. ON 04/21/2000 ANOTHER BLOWOUT OCCCURRE AND WE PURCHASED 1 MORE FIRESTONE ATX TIRE. RECEIPT SHOWS P225/75/R15. IN TOTAL, WE HAVE HAD 3 BLOWOUTS ON FIRESTONE ATX TIRES, ALL BLOWOUTS WERE ON THE SAME VAN. TIRES AFFECTED WERE IN DIFFERENT LOCATIONSON THE VAN. 2 BLOWOUTS OCCURRED GOING 70 MPH; ONE OCCURRED AT 11 PM AT NIGHT, THE OTHER 10 AM IN THE MORNING. THE THIRD OCCURRED ON CITY BY-PASS ROAD ABOUT 5 PM. VAN HAS HAD REGULAR MAINTENANCE AT CHEVY DEALER; I HAVE RECEIPTS SHOWING REGULAR TIRE CHECKS AND ROTATIONS. WE HAVE REMOVED THE FIRESTONE ATX TIRES FROM OUR VAN AND HAVE REPLACED THEM WITH COMPETITOR TIRES. I HAVE RETAINED THE FIRESTONE TIRES--THEY HAVE LESS THAN 4,000 MILES ON THEM...THANKS FOR YOUR HELP, AND "LISTENING". *AK( DOT NUMBER: UNKNOWN TIRE SIZE: P255/75R15 )

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1999-11-23

VISIBILITY PROBLEM

Date Of Incident: 1997-07-23
VIN: 1GBFG15MXT1
Components: VISIBILITY
Summary: EXTERIOR SIDE VIEW MIRRORS - BOTH SIDES VIBRATE AT INCREASE IN SPEED, LOSS OF VISIBILITY TO REAR VIEW. *AK

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1999-06-30

SUSPENSION PROBLEM

Date Of Incident: 1996-10-25
VIN: 1GCGG39K0TF
Components: SUSPENSION
Summary: VAN IS VERY HARD TO CONTROL. IT WHIPS FROM SIDE TO SIDE EVEN ON SMOOTH ROADS. WHEN ON ROUGH ROAD THE FRONT END SHAKES VIOLENTLY AND SOUND LIKE THE FRONT END IS FALLING OUT. VAN HAS BEEN TAKEN TO ATZENHOFFER CHEVROLET IN VICTORIA, TX SEVERAL TIMES. OUTCOME IS ALWAYS THE SAME. "THAT IS THE WAY IT IS AND THERE IS NOTHING WE CAN DO ABOUT IT." THANKFULLY WE HAVE HAD NO ACCIDENTS AS A RESULT OF THESE PROBLEMS. WE DESPERATELY WANT THESE PROBLEMS FIXED BEFORE SOMETHING BAD DOES HAPPEN. CHEVROLET DOESNT SEEM TO KNOW HOW TO FIX IT, MAYBE YOU CAN HELP SOLVE THE PROBLEM. *AK

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1999-05-03

VISIBILITY PROBLEM

Date Of Incident: 2024-11-24
Components: VISIBILITY
Summary: LEFT AND RIGHT SIDE MIRRORS VIBRATE WHILE DRIVING, THEY HAVE BEEN REPLACED PREVIOUSLY. NM

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1999-05-03

STRUCTURE PROBLEM

Date Of Incident: 2024-11-24
Components: STRUCTURE
Summary: DOOR HINGES ON REAR AND SIDE FRONT CARGO DOORS FAIL TO KEEP DOORS OPEN WHEN ON AN INCLINE OR WHEN A SLIGHT WIND BLOWS. NM

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1998-06-11

AIR BAGS PROBLEM

Date Of Incident: 2024-11-24
Crash: 1
VIN: 1GC2GG255T1
Components: AIR BAGS
Summary: WHILE PULLING FROM A STOP SIGN VEHICLE WAS STRUCK ON THE LEFT SIDE CORNER PANEL SPEED WAS UNDER 20 MPH. DRIVER'S SIDE AIR BAG DID NOT DEPLOY, BUT PASSENGER'S SIDE DID. *AK

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1998-05-27

SERVICE BRAKES, HYDRAULIC PROBLEM

Date Of Incident: 1997-12-10
VIN: 1GCGK24R9TE
Components: SERVICE BRAKES, HYDRAULIC
Summary: CONSUMER WAS COMING TO A STOP SIGN WHEN APPLIED THE BRAKE PEDAL. WHILE APPLYING THE BRAKES FELT A QUICK POPPING SENSATION. THE BRAKE PEDAL STAYED HARD, BUT IT DID NOT STOP THE VEHCILE. VEHICLE KEPT ON GOING. DEALER NOTIFIED. *AK

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1996-12-02

SEAT BELTS PROBLEM

Date Of Incident: 1996-09-10
VIN: 1GBFG15R5T1
Components: SEAT BELTS
Summary: THE REAR PASSENGER'S SEAT BELT DOES NOT CORRECTLY FIT. THE BELT LAYS ON THE PASSENGER'S FACE AND NOT ON THE SHOULDER. THAT IS VERY DANGEROUS TO THAT PERSON. *AK

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1996 Chevrolet G20 recalls

The National Highway Traffic Safety Administration (NHTSA) has issued 5 recalls for different components of the 1996 Chevrolet G20.

2007-10-24

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.

2006-05-19

Manufacturer: HONEYWELL INTERNATIONAL, INC.
Components: FUEL SYSTEM, GASOLINE
Summary: CERTAIN REPLACEMENT FUEL FILTERS, FRAM BRAND NAME P/N G3727, WITH DATE CODES X52911 THROUGH X60801 SEQUENTIALLY OR X600141 AND A MEXICO COUNTRY OR ORIGIN MARKING ON THE FUEL FILTER HOUSING MANUFACTURED FROM OCTOBER 18, 2005, THROUGH MARCH 21, 2006, SOLD FOR USE ON THE VEHICLES LISTED ABOVE AND ON CERTAIN SCHOOL BUSES. (TO SEE THE SCHOOL BUS ENGINE SIZES, CLICK ON "DOCUMENT SEARCH" AND THEN "BUS APPLICATIONS"). THE CONNECTOR ON THE FUEL FILTER WAS NOT MANUFACTURED TO HONEYWELL'S SPECIFICATION. AS A RESULT, THE O-RING MAY NOT SEAT CORRECTLY ON THE FUEL LINE.
Consequence: THIS CONDITION MAY CAUSE AN INADEQUATE SEAL AT THE CONNECTION, POTENTIALLY LEADING TO A FUEL LEAK. IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.
Remedy: HONEYWELL WILL NOTIFY OWNERS AND REPLACE THE FUEL FILTERS FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 18, 2006. OWNERS MAY CONTACT FRAM CUSTOMER SERVICE AT 1-800-890-2075 (OPTION 1).

1999-07-19

Manufacturer: GENERAL MOTORS CORP.
Components: SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP
Summary: THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. VEHICLE DESCRIPTION: CERTAIN LIGHT DUTY PICKUP TRUCKS, SPORT UTILITY VEHICLES, OR MINIVANS EQUIPPED WITH 3-SENSOR ABS (ANTILOCK BRAKING SYSTEM) EBC4 UNITS.
Consequence: THESE VEHICLES CAN EXPERIENCE EXTENDED STOPPING DISTANCES DURING ABS STOPS ON CERTAIN MULTIPLE SURFACES, INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL MODIFY THE COMPUTER PROGRAM WHICH OPERATES THE ABS UNIT ON SOME VEHICLES, OR REPLACE THE COMPUTER ON OTHERS TO IMPROVE THE PERFORMANCE OF THE ABS ON THESE SURFACES.

1996-09-26

Manufacturer: GENERAL MOTORS CORP.
Components: STEERING:LINKAGES
Summary: THE STEERING LINKAGE ASSEMBY CONTAINS A RELAY ROD TAPERED-STUD ATTACHMENT NUT THAT WAS NOT TORQUED TO PROPER SPECIFICATIONS.
Consequence: THE TAPERED STUD CAN LOOSEN AND THE DRIVER WOULD NOTICE A LAG IN THE RESPONSIVENESS TO STEERING WHEEL INPUTS. EVENTUALLY THE RELAY ROD STUD CAN FRACTURE RESULTING LOSS OF STEERING CONTROL.
Remedy: DEALERS WILL REMOVE THE EXISTING CRIMPED NUT AND INSTALL A NEW NUT TORQUED TO SPECIFICATIONS.

1996-09-26

Manufacturer: GENERAL MOTORS CORP.
Components: ELECTRICAL SYSTEM:WIRING:FUSES AND CIRCUIT BREAKERS
Summary: WATER INTRUSION INTO THE KICK PANEL AREAS IN FRONT OF BOTH THE DRIVER AND PASSENGER DOORS CAN CAUSE A CORROSION PATH BETWEEN THE BATTERY FEED AND THE ELECTRICAL GROUND.
Consequence: THIS CONDITION CAN CAUSE AN ELECTRICAL SHORT LEADING TO IGNITION AND COMBUSION OF THE PLASTICS IN THE ELECTRICAL COMPONENTS OF THE VEHICLE RESULTING IN A VEHICLE FIRE.
Remedy: DEALERS WILL REPLACE THE 25 AMP CIRCUIT BREAKERS WITH 25 AMP FUSES IN THE FUSE BLOCK; REMOVE A TEMPORARY PAPER FUSE-BLOCK COVER; INSTALL A PLASTIC SHIELD OVER THE FUSE BLOCK; REPLACE AND REORIENT THE POWER DOOR LOCK RELAY (IF EQUIPPED); INSPECT THE REMOTE KEYLESS ENTRY MODULE (IF EQUIPPED) FOR SIGNS OF CORROSION, REPLACE IF CORRODED, AND REORIENT IT; AND APPLY ADDITIONAL BODY SEALER IN KEY AREAS.

Additional sources

More sources of information about 1996 Chevrolet G20 problems:

1995/96 G30 common problems? - Chevrolet Forum - Chevy ...

https://chevroletforum.com/forum/express-g-series-vans-30/1995-96-g30-common-problems-100960/

Jun 12, 2020 ... Last year I bought a 95 G20 with a 350 and 130k also. I test drove it, listened and looked for smoke. I got the van as a hobby to work on and ...

Q&A: Common Fixes for 1994 Chevy G20 Van - Expert Advice

https://www.justanswer.com/chevy/1k6lx-g20-van-5-7-liter-cylinder-the-common-fixes-model.html

Nov 12, 2008 ... 1994 Chevrolet G20 Conversion 5.7 Liter Already Tried: Was just wondering what were some common problems with this year make and model ...

Any opinions on 90s Chevy G20 vans? : r/vandwellers

https://www.reddit.com/r/vandwellers/comments/vw1xfg/any_opinions_on_90s_chevy_g20_vans/

Jul 10, 2022 ... I've gotta 96 ... Love my 93 G20, lot of good points in other comments regarding reliability ... transmission slippage, really the only problems I ...

If you have a high mileage Chevy Work Van ..i want to talk to u

https://hvac-talk.com/vbb/threads/52895-If-you-have-a-high-mileage-Chevy-Work-Van-i-want-to-talk-to-u-!

My gmc van,350 engine got to 288,000 miles before cam went flat. ... I just got rid of a 1996 Chevy ... starters and water pumps seem to be the most common problems ...