Hinges broke; doors are unsafe.
The worst 2003 Chevrolet Express 1500 problems
Ranked by number of owner complaints. Mileage and cost come from what owners wrote.
- Fuel system9
- Body2
- Electrical2
- Seat belts2
- Engine1
Problems by type
Tap a problem to see which part fails, at what mileage and in which other years.
- Fuel system9
- Body2
- Electrical2
- Seat belts2
- Engine1
- Locks1
- Seats1
- Steering1
Recalls
No recalls on record for this model year.
Defect investigations
Fuel Filler Pipe Corrosion/Leakage
On August 7, 2012 General Motors (GM) notified the Office of Defects Investigation (ODI) that it will conduct a safety related recall for model year (MY) 2003-2004 Chevrolet Express and GMC Savana vehicles.The recall affects vehicles equipped with a left side cargo door and that were originally sold or currently registered in the corrosion or salt-belt states of Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia and Wisconsin. Dealers are to install a new fuel filler neck. Consumer notification letters will be sent in early October 2012, when sufficient parts are available. ODI has received 12 complaints alleging unique incidents of fuel leakage during refueling of a subject vehicle. Eleven of the complaints occurred on Chevrolet Express vans, and 1 of the complaints involved a GMC Savana. All vehicles were equipped with the left side cargo door option. For vehicles so equipped, water and road debris can become trapped in the protective conduit that covers the fuel filler pipe and may subsequently cause the pipe to corrode. If the corrosion creates a significant perforation in the pipe, fuel may leak onto the ground while refueling the vehicle. An illuminated Check Engine light (on some vehicles) or the presence of fuel odor may also act as precursors to fuel leakage. Fuel in the presence of an ignition source could cause a fire to occur. In their response to ODI's information request, GM reported 24 owner reports and 1 field report alleging fuel filler pipe failure/corrosion in the subject vehicle population. Six additional records were also provided that included the replacement of the fuel filler pipe, however not enough information existed to determine a relation to the alleged problem. After further review of the reports, ODI determined that a total of 27 individual GM reports were related to filler pipe corrosion. The complaints received from both ODI and GM primarily occurred in the corrosion states. During the investigation, the scope of the subject vehicle population was expanded to include MY 2004 Express vans, and MY 2003 and 2004 GMC Savana vans (with V6 engines) also equipped with left hand side door options, since the Savana vans also utilize the same, or substantially similar fuel filler pipe configuration. GM subsequently modified the design of the fuel filler pipe on vehicles equipped with side doors to correct the corrosion concern, so these vehicles do not have the defect issue.The affected vehicle population shown above reflects the total number of vehicles registered in the salt-belt states listed in GM's defect information report (DIR). Prior to the safety recall announcement, GM had issued a special coverage adjustment for vehicles in these states, during which a total of 771 repairs were made. Accordingly the vehicle population noted in the DIR reflects that of the remaining vehicle population.The investigation is closed based on GM's announcement of safety recall 12V388. The reports cited above can be reviewed online at www-odi.the federal safety agency.dot.gov/owners/Searchreference under the following identification (ODI) numbers: 10463398, 10459328, 10456403, 10453725, 10445925, 10443143, 10441615, 10413568, 10413214, 10411911, 10353717, 10259377.
PE11040
Technical service bulletins for the 2003 Chevrolet Express 1500 89
Bulletins tell dealers how to fix known problems. A warranty extension means the manufacturer pays for that repair for longer.
- This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.
- This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.
- Unknown or other
- Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles
- GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities
- This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves...
- This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as...
- This service bulletin provides information for dealers/technicians on Service Programming System (SPS)...
- This Warranty Administration bulletin provides retail and wholesale service personnel with the...
- This bulletin provides information for electrical ground repairs using new General Motors replacement...
2003 Chevrolet Express 1500 fuel economy
Official EPA estimates in miles per gallon (MPGe for electric). Ranges cover trims that share the same engine.
| Engine | Drive | City | Highway | Combined |
|---|---|---|---|---|
| 4.3L 6‑cyl | RWD | 13 | 18 | 15 |
| 5.3L 8‑cyl | RWD | 12 | 17 | 14 |
| 5.3L 8‑cyl | 4WD | 12 | 16 | 13 |
What 2003 Chevrolet Express 1500 owners say
Most recent owner complaints, unedited.
Corroded and leaking fuel filler neck. Foolish design involving dissimilar metals held in contact and surrounded with a conduit which holds water and road salt. Design is destined for failure. Gm has a partial recall for the snow belt. Such a foolish design should be fixed everywhere as it is just a matter of time until failure.
The passenger side swing doors are very hard to open and shut and the drivers side swing doors are in the initial stage of this. The passenger swing door that is first to open (right) does not want to open and doesn't want to shut. I have to force it. The second door (left) is getting worse as well. This is causing the interior light pin in the door jam to not push in all the way, therefore; the lights will not shut off.
Tl* the contact owns a 2003 chevrolet express 1500 van. The contact stated that when fueling the vehicle, fuel sprayed from the filler neck. The dealer diagnosed that fuel filler pipe needed to be replaced. The vehicle had not been repaired. The manufacturer had not been notified. The approximate failure mileage was 107,000.
Tl* the contact owns a 2003 chevrolet express 1500. The contact stated that fuel was leaking from under the vehicle. The vehicle was taken to the dealer and to an independent mechanic for diagnostic testing. The technician and the mechanic advised that the return and delivery fuel lines would have to be replaced due to corrosion. The vehicle was not repaired. The approximate failure mileage was 148,000.
On a few occasions prior to locating a leak, I noticed a gasoline smell. Finally when filling earlier this month, I saw a lot of leaking coming out of the fuel filler tube, between the metal tube and the plastic cover surrounding the tube. When I got home, I cut off the plastic tube about halfway and found a static wire running the length of the tube. Everywhere, where this wire touched to metal pipe, it was corroded completely through. The static wire is of a different material and was not corroded. Presently I have wrapped the tube with a gasoline resistant tape. But, I will have to replace the tube soon. The local dealership has quoted approx. $241.00 without installation. Are there other instances like this and is there a recall I'm not aware of. Thank you for your time.
For sometime, there was a smell of gasoline when filling this van, which I just attributed to a vapor release when the tank was full. Recently, I notice gas leaking under the van when filling at the gas station. The gas leaks in and around the brake lines. This van is a 2003 chevrolet express 1500 with left hand door option. This is my family vehicle and in researching this problem further, I understand it to be a known problem and a design flaw, where the fuel fill hose rusts. This needs a recall with immediate attention.
I was refueling my van and gas started pouring out from the bottom. After looking I discovered the fuel filler neck was rusted thru. The van only has 64k miles. I replaced it myself at this time. There was no collision damage....simply heavy corrosion.
Tl* the contact owns a 2003 chevrolet express 1500. The contact stated that after refueling, he noticed an overpowering fuel odor. The contact further inspected the vehicle and found that the fuel tank was leaking and rusted. The vehicle was inspected by the dealer and they advised the contact that the gasoline filler tube needed to be replaced. The vehicle was not repaired. The manufacturer was contacted and they offered no assistance. The failure mileage was approximately 64,000. Updated 02/13/12
Gas filler tube rusted through and gasoline leaked every time I refueled. This was not a small hole. The metal on the whole tube broke down causing fuel to leak and creating a fire hazard. Updated 08/11/11 *bf updated 3/08/2012 *ln
Compare the 2003 Chevrolet Express 1500
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Questions about the 2003 Chevrolet Express 1500
Is the 2003 Chevrolet Express 1500 reliable?
Owners have filed 18 complaints about the 2003 Chevrolet Express 1500, 3.6 times a typical Express 1500 model year.
What is the most common problem with the 2003 Chevrolet Express 1500?
Fuel and propulsion system, with 9 complaints, typically around 107,000 miles. Next is body (2).
How many recalls does the 2003 Chevrolet Express 1500 have?
No recalls on record.
What gas mileage does the 2003 Chevrolet Express 1500 get?
Official estimates for the 2003 Chevrolet Express 1500 range from 13 to 15 mpg combined. The most efficient version (4.3L 6-cyl, RWD) gets 13 city and 18 highway.
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