Problems owners report
Complaints filed with NHTSA about the 2003 Chevrolet Express, by the system named in each complaint. One complaint can name several.
- Electrical system10
- Service brakes, hydraulic8
- Power train6
- Fuel/propulsion system6
- Structure5
- Seat belts4
- Fuel system, gasoline4
- Air bags4
- Engine4
- Steering3
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 1 injuries and 0 deaths reported
Compared with other years
NHTSA ODI complaints by model year
Fatal crashes in the US
From 2020 to 2023, 27 2003 Express vehicles were involved in crashes on US public roads in which someone died; 16 people died inside them, and 4 of the vehicles rolled over. This is a count, not a crash rate: it grows with the number of cars on the road.
NHTSA Fatality Analysis Reporting System (FARS), crash years 2020–2023 (public domain)
New York safety inspections
At its first New York inspection the 2003 Chevrolet Express failed the safety check 1.40% of the time — 34% less often than the average 2003 passenger car (2.11%). Median odometer at inspection: 158,615 miles.
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
In the Netherlands
31 first registered in 2003 are on Dutch roads; 97% arrived later as imports.
Most common APK defects
- Stuur- of fuseekogel met slijtage kleiner of gelijk 1,0 mm29
- Overmatige vloeistoflekkage overige vloeistoffen23
- Bandenspanning niet op juiste waarde19
- Dimlicht onjuist afgesteld10
- Remvertraging / remwerking parkeerrem onvoldoende6
- Roestschade dorpel5
- Ruitenwisserinstallatie geeft onvoldoende zicht4
- Band onvoldoende profiel4
Colours
RDW Open Data: registered vehicles and APK defects (CC0) · defect descriptions in the RDW's Dutch wording
In New Zealand
1 2003 cars are on the New Zealand register; 100% arrived as used imports, 0% were sold new in New Zealand.
NZ Transport Agency Waka Kotahi, Motor Vehicle Register (March 2026) · CC BY 4.0
Fuel consumption
Official Canadian test results for 3 variants: combined 18.9–19.7 L/100 km (about 12 mpg US), CO₂ 357–453 g/km.
| Variant | City | Highway | Combined |
|---|---|---|---|
| Express Cargo Bi-Fuel · Van: Cargo · Natural gas | 21.8 | 15.3 | 18.9 |
| Express Cargo CNG · Van: Cargo · Natural gas | 21.8 | 15.3 | 18.9 |
| Express Cargo Bi-Fuel · Van: Cargo · Regular gasoline | 23.6 | 14.9 | 19.7 |
Litres per 100 km. Natural Resources Canada, Fuel consumption ratings (open.canada.ca) · Open Government Licence – Canada
Recalls in Canada
13 Transport Canada recalls for the 2003 Chevrolet Express.
| 2023210 6 Apr 2023 | Electrical Issue: On certain vehicles, an unused wiring harness for a rear HVAC blower motor, located in the left B-pillar area, could become damaged if exposed to moist… |
| 2012265 8 Aug 2012 | Fuel System On certain vehicles equipped with a left side cargo door, and originally sold in or currently operated in areas of heavy road salt usage during winter months (O… |
| 2008120 10 Apr 2008 | Seats And Restraints Certain full-size passenger, cargo and cutaway vans may have front and rear seat belt buckles that will not latch or will not unlatch. There are two conditions… |
| 2005390 14 Dec 2005 | Seats And Restraints Certain full-size passenger, cargo and cutaway vans may have front and rear seat belt buckles that will not latch or will not unlatch. There are two conditions… |
| 2004216 7 Jul 2004 | Other On certain vehicles, the transmission shift cable may allow the transmission indicator (PRNDL) to indicate a different gear selected than the transmission is in… |
| 2004037 29 Jan 2004 | Brakes On certain vehicles, the relief valve o-ring seal within the brake hydro-boost module could fail. If this happens during braking applications, the driver may b… |
| 2003294 26 Nov 2003 | Visual System Certain vehicles do not comply with either CMVSS 105, or CMVSS 135. The red brake warning indicator will not be illuminated while the ABS is modulating the fro… |
| 2003172 16 Jul 2003 | Seats And Restraints Certain vehicles do not comply with CMVSS 225 and 210.2. The Owner's Manual does not include the location symbols for the Lower Universal Anchorage System for … |
| 2003154 16 Jun 2003 | Electrical On certain vehicles, water may enter and corrode the rear licence plate lamp socket causing it to operate intermittently or not at all. The left rear tail lamp… |
| 2003040 19 Feb 2003 | Seats And Restraints On certain vehicles, the seat belt push button may not release the latch plate after the pretensioner is deployed, or alternately the seat belt latch plate may … |
| 2002237 12 Dec 2002 | Steering On certain 2500 and 3500 series vans, the nut attaching the pitman arm to the steering linkage may not be torqued to specification, which could lead to a possib… |
| 2002225 22 Nov 2002 | Steering On certain vehicles, the right-hand tie rod end nut may not have been torqued to specification and could loosen, resulting in separation of the tie rod. This c… |
| 2002211 15 Nov 2002 | Suspension On certain 2500 and 3500 series vehicles, a wheel bearing assembly retaining nut was omitted during assembly, which could lead to a possible bearing separation.… |
Transport Canada Vehicle Recalls Database · Contains information licensed under the Open Government Licence – Canada
Recalls
General Motors (GM) is recalling certain model year 2003-2004 Chevrolet Express and GMC Savana vehicles, equipped with a left side cargo door, and originally sold or currently registered in Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin, and the District of Columbia. Water and road contaminants may become trapped in the protective conduit that covers the fuel filler pipe and may cause the pipe to corrode.
ON CERTAIN FULL-SIZE PASSENGER, CARGO, OR CUTAWAY VANS, THE FRONT AND REAR SEAT BELT BUCKLES WILL NOT LATCH OR WILL NOT UNLATCH.
CERTAIN EXTENDED AND REGULAR CAB PICKUP TRUCKS AND CARGO VANS CONVERTED TO COMPRESSED NATURAL GAS (CNG) FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 225, 'CHILD RESTRAINT ANCHORAGE SYSTEMS.' THESE VEHICLES HAVE ONE SEATING POSITION, THE CENTER REAR SEAT, EQUIPPED WITH CHILD RESTRAINT LOWER ANCHORAGES.
CERTAIN SPORT UTILITY VEHICLES, PICKUP TRUCKS, AND PASSENGER VANS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 135, ?PASSENGER CAR BRAKE SYSTEMS.? SOME OF THESE VEHICLES WERE PRODUCED WITH AN OUT-OF-SPECIFICATION BRAKE HYDRO-BOOST HOUSING RELIEF VALVE BORE.
CERTAIN MINIVANS, PASSENGER AND SPORT UTILITY VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 225, "CHILD RESTRAINT ANCHORAGE SYSTEM." THE OWNER'S MANUAL DOES NOT EXPLAIN THE MEANING OF THE LOCATION SYMBOLS FOR THE CHILD RESTRAINT LOWER UNIVERSAL ANCHORAGE SYSTEM.
CERTAIN VANS HAVE A CONDITION IN WHICH WATER MAY ENTER AND CORRODE THE REAR LICENSE PLATE LAMP SOCKET. IF THE LAMP SOCKET WERE TO CORRODE, THE REAR LICENSE PLATE LAMP MAY OPERATE INTERMITTENTLY OR NOT AT ALL, AND THE LEFT REAR TAIL LAMP MAY BECOME INOPERATIVE. THE TEMPERATURE OF THE LICENSE PLATE LAMP SOCKET COULD INCREASE TO THE POINT THAT IT MAY BEGIN TO SOFTEN AND MELT.
ON CERTAIN VANS WITH A GROSS VEHICLE WEIGHT OF LESS THAN 8,500 POUNDS, DURING A VEHICLE CRASH SUFFICIENT ENOUGH TO DEPLOY THE SAFETY BELT PRETENSIONER, THE FRONT SAFETY BELT BUCKLES MAY NOT RELEASE AFTER THE VEHICLE CRASH, OR ALTERNATELY MAY EJECT THE SAFETY BELT LATCH DURING THE VEHICLE CRASH.
ON CERTAIN VANS WITH AN 8,500 LB. OR 8,600 LB. GROSS VEHICLE WEIGHT RATING, THE NUT ATTACHING THE PITMAN ARM TO THE STEERING LINKAGE MAY NOT BE TIGHTENED ADEQUATELY RESULTING IN A POSSIBLE SEPARATION.
ON CERTAIN VANS, THE RIGHT-HAND TIE ROD END NUT MAY NOT BE TIGHTENED ADEQUATELY. THE NUT CAN LOOSEN RESULTING IN SEPARATION OF THE TIE ROD FROM THE STEERING KNUCKLE.
CERTAIN VANS WERE BUILT WITHOUT A WHEEL BEARING ASSEMBLY RETAINING NUT, WHICH COULD LEAD TO A POSSIBLE BEARING SEPARATION.
Whether a recall was fixed on a particular car is known only to the manufacturer: check the VIN at nhtsa.gov/recalls.
NHTSA recalls · summaries in NHTSA's own words
Service bulletins
What Chevrolet told its dealers about the 2003 Chevrolet Express: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 634999 | DIAGNOSIS OF CRACKED OR BROKEN TRANSMISSION CASE. *TT 2006 AND PRIOR CARS AND LIGHT DUTY TRUCKS. *TT |
| 634841 | SUBJECT REGARDING DIAGNOSTIC TROUBLE CODE C0201 SET AND STORED IN HISTORY. *TT |
| 620827 | VIBRATION OR RATTLE-TYPE NOISE COMING FROM THE EXHAUST SYSTEM AT IDLE WITH ENGINE RPMS BETWEEN 613 AND 712. *TT THIS BULLETIN REPLACED 01-06-05-003 DATED 07/01/2001. *TT |
| 11010544 | This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil. |
| 11009156 | This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester and Vehicle Data Recorder tools, giving website address and step by step instructions to complete the update. |
| 11007744 | This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature. |
| 11007743 | This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature. |
| 11007208 | This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed for the vehicle in question and its applications. Technician should not use the information that is provided by the antilock braking system tire size selection. |
| 11006621 | Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected modules (with some exceptions). The updating of modules is completed in parallel instead of the technician needing to update one module at a time. This allows a more streamlined approach for dealers and customers. |
| 11006421 | GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the dealers to be more careful not to damage the transmissions during removal and to package the core properly for return. |
| 11004761 | This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up. |
| 11004557 | This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim. |
| 11002312 | This service bulletin provides information for dealers/technicians on Service Programming System (SPS) Error Codes E4398, E4399, E4401, E4403, M4404, M4413, M6954, M6955, E4414, E4423, E4491, E4492, or E6961 and resolution information. |
| 11000576 | This Warranty Administration bulletin provides retail and wholesale service personnel with the policies/procedures and the warranty transaction submission procedures that support the Personal Property Damage process. |
| 10252735 | This bulletin provides information for electrical ground repairs using new General Motors replacement fasteners with conductive finish. |
| 10252163 | XM Audio Traffic And Travel Link Availability And Operation. |
| 10251890 | This technical bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up. |
| 10250775 | This service bulletin provides service information to technicians on guidelines to replace Oil Cooler, Oil Cooler Lines and Oil Tank if the engine was replaced where large amounts of debris has flowed throughout the oiling system. |
| 10249980 | This Preliminary Information communication provides information to the technician about vibration complaints that are one of the most challenging complaints to accurately diagnose and repair. Technician will need to use Pico Oscilloscope Diagnostic Kit to effectively diagnosis vehicles. Technician should drive the vehicle will using the Pico Oscilloscope to record data. After the data is recorded it should be reviewed to determine the root cause of the concern. If a repair attempt made the concern better but not eliminated or had no affect at all, and are requesting assistance from General Mot |
| 10249590 | This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim. |
| 10249579 | This PI bulletin advises the technician on the proper way to install the pistons in an engine. |
| 10249011 | This informational bulletin provides information for dealers/technicians on Headlamp, Tail Lamp, License Lamp or Fog/Driving Lamp Damage. |
| 10248444 | Vehicle Recalls |
| 10247780 | This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature. |
| 10247681 | Information On Requests To Add OnStar Bluetooth Option. |
NHTSA manufacturer communications (public domain)
NHTSA investigations
Fuel Filler Pipe Corrosion/Leakage
HYDRAULIC PUMP FAILRES
NHTSA Office of Defects Investigation