Several of the exhaust header bolts are broken on both sides of my 5.3 litter engine. I did some internet searching and found a lot of people with 5.3 litter engines having the same issue.
The worst 2003 Chevrolet Express 2500 problems
Ranked by number of owner complaints. Mileage and cost come from what owners wrote.
- Brakes5
- Fuel system3
- Body2
- Engine1
- Steering1
Problems by type
Tap a problem to see which part fails, at what mileage and in which other years.
- Brakes5
- Fuel system3
- Body2
- Engine1
- Steering1
- Suspension1
- Transmission1
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 2500 90
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...
What 2003 Chevrolet Express 2500 owners say
Most recent owner complaints, unedited.
I was traveling on the highway at the speed of 50 MPH and the van suddenly began to violently shake and shudder from the front wheels and up and including the shake of the steering wheel. I slowed the vehicle down by braking to 35 MPH and it slowly stopped shaking. This has become a regular issue with the vehicle and I have taken it from shop to shop and mechanics cannot figure out the problem. I fear for my family's safety as well as my own when driving alone in this vehicle. It has been a year since this has begun. Mechanic has changed the shocks for the van and it has began to violently shake and shudder more frequently. I need to know why this is happening. I own a chevrolet express 2500 (2003).
I have a 2003 chevrolet express van 2500 that the paint just started falling off in large flakes on the rear and side doors, and the front hood. I have tried touch up paint to try and stop the peeling, but it has not helped.when I wash the vehicle or it rains makes the problem worsen by filling up pockets behind the paint. This is a my company van which has decal lettering on it. The flaking is starting to get to the lettering. If it continues, I will loose approx. $800.00 to a $1000.00 in decal lettering plus the van looks terrible for a company van. The color of the van is white. I have noticed many gm cars around where I live that have this problem. I never really noticed until my van started to do it. Many of our city police cars where I live are white gm products and have paint peel on them.why is gm not correcting this issue? What can I do to get this problem corrected? I have other gm products I own. I am not sure if I will purchase another due to problems showing up years down the road that should not exist if their product is a quality product and gm stands behind their quality of what they produce. Now I am faced with the cost of a paint job and the cost of relettering the van. The smarter answer may be to buy another van of another make and stay away from gm if they cannot stand behind their product quality. I have read too many articles about paint peel on gm products since investigating this issue. Many suggest small claims courts because gm will do nothing about it. Need help if there is any suggestions.
Filling up the van, notice that gasoline was leaking from the fuel filler tube. Investigation concluded that the plastic corrigated wrap that chevy placed on the tube, traps water, salt, dirt, ect... In it, allowing the pipe to rust, without the driver/owner noticing the damage until it starts leaking. As a firefighter, I realize the dangers of gasoline leaking under a vehicle, I feel that this is a serious design flaw for the filler tube.
Chevy 2003 express van fuel filler neck has rusted through in 2 places and gas pours out every time I refuel. Only 63,000 miles on van. I believe this I s a very serious fire hazard!!! Is there a recall?
Since approximately january of 2010, family members noticed an increasing amount of fuel leaking on the ground during fueling. After further investigation, I noticed it originated from the fuel filler tube which allows the gas to travel from the gas cap to the gas storage tank. August 2010, the leakage became so severe from the fuel filler tube I feared someone could ignite (I.e. Cigarette, cell phone, static charge) the 1 to 2 gallons of fuel leaked at the pump. My express was only out-of-commission at dealership for 2 days to replace the fuel filler tube. Dropping a at the time of fill up. The repair cost $167.00 and the dealership who repaired my 2003 chevy passenger express van said, "... The cause was a park brake cable rubbing on the tube." as a consumer and automotive engineer, I feel the manufacturer is responsible for this design defect. The dealership simply indicated they never seen this on the express. It appears this is more than an isolated occurrence.
Under normal use rear side door is hard to open or close and now broken. The door, even before it was broke was hard to latch if it would latch. This would make the front side door not close tight. Now with the hinge broken the door does not latch correctly. All express vans have this same problem and manufacture knows it. I tried using every penetrating oil and it would not keep the door hinge from seizing up. This is a company van and we have 2 of them with broken hinges (both are the top rear on the side door) and a 3rd that is very hard to open close. If this were a passenger type the door could be hit on the inside and opened by accident. We are in the process of locating a hinge to replace the one on the van I drive and was told by the local dealer to keep all receipts incase of a recall. I was told it would be around $1200 to fix 1 door. I do not have the VIN at this time, but during the day I am with the van 7am to 4pm .
While driving on a two lane mountain road between oakhurst, california and yosemite I observed a front end vibration coming through the steering wheel. I pulled over and could find nothing wrong so I made a u-turn and went to oakhurst to effect a repair. I barely made it to town to a shop when the left front bearing assembly failed ,requiring the entire unit to be replaced. The shop was surprised that the wheel had not come off. The cost was $520 ,and necessitated an overnight stay due to the part having to be brought in from fresno. I had purchased the vehicle new, but it was three weeks out of warranty. The mileage was 25,000. I took the part to my local chevrolet dealer, they informed me in writing that the bearing had inadequate lubrication at the factory. The other bearing was pulled, and it was okay. Gm has totally ducked any form of reimbursement. I am just thankful that we did not have a accident on that mountain road
Brake failure on 2003 chevy express 2500 cargo van. Gm knows about this problem, see general motors tsb #'s..03-05-25-003 & 02-05-25-005 & 05-05-25-002. This should be fixed via a "safety recall " since the only way to fix the vehicle is to have the ABS computer reprogrammed at a chevy or gmc dealer. This is an obvious manufacturing error as noted by the tsb's, & should be repaired free of charge. No amount of normal servicing could prevent this from occurring. I've called gm re. This & they say it's not a safety issue?????? Loss of brakes is not a safety issue ??? The dealer charged me $90. To correct their programming error.
Tl*- the contact stated that the brakes on the 2003 chevrolet express were defective due to a program error in the ABS computer system per general motors. Therewas not failure to date, but the contactwas concerned. General motors has three (3) service bulletins to date concerning these brakes. 03-05-25-003, 02-05-25-005, 05-05-25-002.
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Questions about the 2003 Chevrolet Express 2500
Is the 2003 Chevrolet Express 2500 reliable?
Owners have filed 12 complaints about the 2003 Chevrolet Express 2500, 1.7 times a typical Express 2500 model year.
What is the most common problem with the 2003 Chevrolet Express 2500?
Brakes, with 5 complaints. Next is fuel system (3).
How many recalls does the 2003 Chevrolet Express 2500 have?
No recalls on record.
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