Chevrolet G3500 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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Chevrolet G3500 model years
Common Chevrolet G3500 problems
The Chevrolet G3500, also known as the Chevrolet Express 3500, is a popular choice for commercial vehicles due to its spacious interior and powerful engine. However, like any vehicle, it is not immune to issues and complaints from owners. Here are some of the common problems with the Chevrolet G3500 based on complaints from owners:
1. Fuel Filter Issues
The fuel filter is a crucial component of the vehicle's fuel system, and it is responsible for filtering out impurities and debris before they reach the fuel injectors. According to RepairPal, one of the most common issues with the GMC G3500 is related to the fuel filter. Car owners have reported that the fuel filter can become clogged or dirty, which can lead to fuel pump failure. To prevent this issue, it is recommended to replace the fuel filter every 30,000 miles.
2. Tire Recall
In February 2021, General Motors, LLC (GM) announced a recall for certain 2018-2021 Chevrolet Express vehicles due to a tire issue. The affected tires were cured for too long during production, which can cause the tire to crack and separate from the wheel, increasing the risk of a crash. GM will notify owners, and dealers will inspect the tires, replacing them as necessary, free of charge.
3. Electrical System Recall
In March 2021, GM announced a recall for certain 2021 Chevrolet Express vehicles equipped with 6.6L gasoline engines due to an electrical system issue. The positive battery cable terminals may contact a fuse block assembly attachment post and cause an electrical short circuit. GM will notify owners, and dealers will remove a portion of the anti-rotation tab on both positive battery cable terminals near the fuse block assembly attachments, free of charge. If too much of the tab had been removed during prior servicing, the battery cable will be replaced, free of charge.
4. Brake System Recall
In February 2005, GM announced a recall for certain 2004 Chevrolet Express 3500 vehicles due to a brake system issue. The hydro-boost brake assembly pressure accumulator may crack and separate from the hydro-boost assembly during normal operating conditions. If this were to occur, the ABS system would be disabled, and the driver would notice a grinding noise, a decrease in the vehicle speed, and the steering will pull in the direction of the affected brake assembly. This could result in a loss of vehicle control, increasing the risk of a crash. Dealers will test the hydro-boost assembly for functional operation of the two-function valve. If the hydro-boost assembly fails the test, dealers are to replace the assembly.
5. Wheel Bearing Issues
Some of the 2003 Chevrolet Express 3500 vans were built without a wheel bearing assembly retaining nut, which could lead to a possible bearing separation. If this were to occur, the ABS system would be disabled, and the driver would notice a grinding noise, a decrease in the vehicle speed, and the steering will pull in the direction of the affected brake assembly. This could result in a loss of vehicle control, increasing the risk of a crash. Dealers will inspect the wheel bearing assembly. If the inspection reveals a missing retaining nut, the wheel bearing assembly will be replaced.
6. Safety Belt Pretensioner Issues
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, or may cause the buckle to unlatch in a crash, resulting in an increased risk of personal injury. Dealers will replace the front driver and passenger side safety belt buckle.
7. Engine Issues
According to ChevroletProblems.com, the Express ranks 7th in reliability out of 40 Chevrolet models, and owners have made 74 complaints over 25 model years, mostly about engine issues.
8. Starting and Idling Problems
Some owners have reported problems with starting and idling the vehicle. This can be caused by the throttle plate not seating properly, which can cause all sorts of idle and hesitation problems.
In conclusion, while the Chevrolet G3500 is a powerful and spacious commercial vehicle, it is not immune to issues and complaints from owners. Common problems include fuel filter issues, tire recalls, electrical system recalls, brake system recalls, wheel bearing issues, safety belt pretensioner issues, engine issues, and starting and idling problems. It is important for owners to stay up-to-date with recalls and maintenance to ensure the safety and reliability of their vehicle.
Are Chevy Express 3500 vans reliable?
The probability of a repair being a severe or major issue is 19% for the Chevrolet Express 3500, compared to an average of 16% for commercial vans and 12% for all vehicle models. The average total annual cost for unscheduled repairs and maintenance across all model years of a vehicle.
How much does a Chevy Express g3500 weight?
5266 pounds 5487 pounds
2023 Chevrolet Express 3500 Cargo Specs, Features & Options
| Curb Weight | |
|---|---|
| 5266 pounds | 5487 pounds |
| Fuel Capacity | |
| 31 gallons | 31 gallons |
| Front Head Room |
Is Chevy Van 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.
What was the last year for Chevy van?
2025-2026
In February 2024, GM abandoned its plans to produce an electric full-size van; the status of the GMT620 redesign is also unknown, leaving the model line without a replacement beyond the 2025-2026 model year.
Percentage distribution of complaints by Chevrolet G3500 years
We have researched Chevrolet problems and analysed all the complaints filed against Chevrolet G3500 cars and compiled the top 3 most problematic Chevrolet G3500 model years:
Below you can see the percentage distribution of known problems by Chevrolet G3500 model years.
Distribution of the number of complaints by Chevrolet G3500 years
We've also compiled a chart for you with the number of complaints about Volkswagen Jetta cars of certain model years:
Chevrolet G3500 car problems categorized by type of issue
After analysing all complaints related to Chevrolet G3500 , it was concluded that the most common issues with these cars are:
- Steering problems
- Suspension problems
- Power train problems
- Tires problems
- Service brakes problems
The graph below shows statistics for all Chevrolet G3500 vehicle components and the number of complaints received.
The NHTSA has received 4 complaints about various vehicle components related to the Chevrolet G3500 . Below are the 25 most recent complaints reported for Chevrolet G3500 vehicles.
List of Chevrolet G3500 complaints
Chevrolet G3500 2008
- Date Of Incident: 2009-03-01
- Date Complaint: 2018-01-16
- VIN: 1GBJG31K581
- Components: FUEL SYSTEM, GASOLINE
- Summary: TL* THE CONTACT OWNS A 2008 CHEVROLET EXPRESS (MOTORHOME). WHILE THE VEHICLE WAS STATIONARY, THE FUEL TANK WOULD NOT FILL UP WHEN PROMPTED. THE VEHICLE WAS TAKEN TO DAVE ARBOGAST BUICK GMC IN TROY, OHIO WHERE IT WAS DIAGNOSED THAT THE FUEL TANK NECK WAS TOO SMALL TO GATHER THE FUEL INTO THE TANK. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 47,000. *TT *TR
Chevrolet G3500 2005
- Date Of Incident: 2012-10-15
- Date Complaint: 2012-10-15
- Components: TIRES
- Summary: TL* THE CONTACT OWNS A 2005 CHEVROLET G3500 EQUIPPED WITH BF GOODRICH COMMERCIAL TA A/S TIRES, SIZE: LT245/75R16. THE CONTACT STATED THAT HE RECEIVED NOTIFICATION OF NHTSA CAMPAIGN ID NUMBER: 12T019000 (TIRES:TREAD/BELT). THE CONTACT WENT TO THE DEALER TO HAVE THE TIRES CHANGED BUT THE DEALER ADVISED THAT THE CONTACT WOULD HAVE TO FIRST PURCHASE THE TIRES AT FULL PRICE IN ORDER TO BECOME ELIGIBLE FOR A REIMBURSEMENT. THE TIRES WERE NOT REPLACED. THE FAILURE MILEAGE WAS 160,000. THE VIN WAS NOT AVAILABLE.
Chevrolet G3500 2005
- Date Of Incident: 2011-05-04
- Date Complaint: 2011-05-04
- VIN: 1GAHG39U851
- Components: SERVICE BRAKES, HYDRAULIC
- Summary: BRAKE LINE RUBBING AGAINST FRAME ON THE FRONT LEFT SIDE OF VAN. LOST OF FLUID AND BRAKE PERFORMANCE.
Chevrolet G3500 2004
- Date Of Incident: 2010-02-15
- Date Complaint: 2010-02-18
- VIN: 1GCHK33214F
- Components: STEERING,SUSPENSION,POWER TRAIN
- Summary: FRONT WHEEL BEARING/HUB FAILURE ON CHEVY SILVERADO HD 4WD DURAMAX PICKUPS: I AND SEVERAL FRIENDS OWNING THE SAME VEHICLES HAVE ALL EXPERIENCED FRONT WHEEL BEARING/HUB FAILURE AT BETWEEN 60,000 TO 80,000 MILES. THIS APPEARS TO BE A SAFETY ISSUE AND GM WILL NOT RECOGNIZE THIS KNOWN ISSUE. THIS ASSEMBLY IS NOT ENGINEERED PROPERLY AND CANNOT HOLD UP TO THE WEIGHT OF THE DIESEL AND 4WD COMPONENTS. THE SAME HUB ASSEMBLY IS USED IN GM GAS ENGINE POWERED HD TRUCKS AND THERE DOESN'T SEEM TO BE AN ISSUE. THERE IS ABSOLUTELY NO REASON FOR THESE TO EVER GO OUT. I AVERAGE ABOUT 13K MILES A YEAR, WELL BELOW THE AVERAGE NUMBER OF YEARLY DRIVEN MILES, AND THE DRIVER SIDE FAILED AT 70K AND PASSENGER SIDE AT 77K. THIS IS A SEALED REMOVE AND REPLACE UNIT THAT SEEMS TO BE POORLY ENGINEERED AND I FEEL THERE SHOULD BE A RECALL ISSUED. *TR
Recalls Chevrolet G3500
The National Highway Traffic Safety Administration (NHTSA) has issued 3 recalls for different components of the Chevrolet G3500.You can explore the year of the Volkswagen Jetta you are interested in by selecting it from the list.
- Model: Chevrolet G3500 2008
- Report Received Date: 2014-04-16
- Manufacturer: Cummings Mobility Conversion & Supply, I
- Components: EQUIPMENT ADAPTIVE/MOBILITY
- Summary: Cummings Mobility Conversion & Supply, Inc. (Cummings) is recalling various model year 1994-2011 Ford and Chevrolet vans equipped with Braun NCL-2, and NVL-2 wheel chair lifts manufactured November 20, 2006, through September 10, 2010. Over time, and with frequent use, the roll stop latches on the outer barrier of the lifts in these vans may become bent or misaligned.
- Consequence: A wheelchair occupant may defeat or ride over the insufficiently latched roll stop. If this occurs when the lift platform is in an elevated position, the wheelchair's occupant could fall and sustain injury.
- Remedy: Braun Corporation notified all the vehicle owners, and Cummings Mobility replaced the recalled parts with new parts, free of charge. The recall was completed as of April 10, 2014. Owners may contact Cummings customer service at 1-800-639-5438.
- Model: Chevrolet G3500 2005
- Report Received Date: 2009-07-14
- Manufacturer: WEST TEXAS REHABILITATION CENTER
- Components: EQUIPMENT ADAPTIVE/MOBILITY
- Summary: WEST TEXAS REHABILIATION CENTER IS RECALLING 1 MY 2005 CHEVROLET G3500 VAN AND 1 MY 2006 FORD E-150 VAN EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 403, "PLATFORM LIFT INSTALLATIONS IN MOTOR VEHICLES." THE THRESHOLD WARNING SYSTEM MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER IN A CERTAIN SPOT WITHIN THE DEFINED THRESHOLD AREA.
- Consequence: THE USER OF THE LIFT COULD BE INJURED SHOULD THE LIFT MOVE UNINTENTIONALLY.
- Remedy: WEST TEXAS IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PLEASE SEE 07E095). OWNERS MAY CONTACT RICON AT 1-818-267-3000 OR WEST TEXAS AT 1-325-793-3546.
- Model: Chevrolet G3500 2005
- Report Received Date: 2009-07-14
- Manufacturer: WEST TEXAS REHABILITATION CENTER
- Components: EQUIPMENT ADAPTIVE/MOBILITY
- Summary: WEST TEXAS REHABILIATION CENTER IS RECALLING 1 MY 2005 CHEVROLET G3500 VAN AND 1 MY 2006 FORD E-150 VAN EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 403, "PLATFORM LIFT INSTALLATIONS IN MOTOR VEHICLES." THE ANTI-STOW INTERLOCK MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER. THE PRESSURE SENSING SWITCH THAT DETECTS THE PRESENCE OF WEIGHT ON THE PLATFORM WAS NOT ADJUSTED TO THE NECESSARY SENSITIVITY LEVEL. THE LIFT COULD STOW EVEN THOUGH SOMEONE OR SOMETHING IS STILL ON THE LIFT.
- Consequence: THE USER OF THE LIFT COULD BE INJURED SHOULD THE LIFT MOVE UNINTENTIONALLY.
- Remedy: WEST TEXAS IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PLEASE SEE 07E097). OWNERS MAY CONTACT RICON AT 1-818-267-3000 OR WEST TEXAS AT 1-325-793-3546.
Are you having problems with your Chevrolet G3500?
