Summary
The Chevrolet Express has 17 recalls spanning 2003 through 2025, with the most serious recent issues being defective tire sidewalls on certain 2025 cutaway chassis vehicles that can fail suddenly and cause loss of control, and a battery cable contact with the fuse block on 2021 6.6L gasoline models that can cause an electrical short and start a fire.
The 2025 model year also has a front passenger seat head restraint that may be poorly welded to the seat frame and can fail to protect the occupant in a crash. On 2016-2018 models with a single manual rear climate control module, an electrical short at the module can overheat the headliner and start a fire. The 2014-2017 model years have a driver's power window switch that can let liquid intrude, corrode its contacts, and create enough electrical resistance to cause a fire. Certain 2017-2019 vehicles fitted with aftermarket backup camera monitors display a mirrored image that can cause the driver to steer in the wrong direction while reversing. Some 2016-2017 models were built without an inside rearview mirror, reducing rear visibility. The 2018 model year has a tire pressure monitoring system calibrated to warn at 37 PSI instead of the correct 41 PSI, giving drivers less time to react to a low-pressure condition.
On 2013 models, a manufacturing window meant the ignition key could be removed while the engine was still running or the transmission was out of Park, allowing the vehicle to roll away. Going back further, 2011-2014 models equipped with compressed natural gas (CNG) systems can leak natural gas from the high-pressure regulator, raising the risk of fire or explosion near any ignition source. A separate issue on certain 2011 CNG conversion vehicles allows the pressure relief device to vent natural gas directly into the passenger compartment if the vent pipe was improperly assembled. The 2010 model year has a voltage regulator inside the generator that can develop an internal short, build heat over time, and ignite a fire in the engine compartment. On 2008-2010 wheelchair lift-equipped conversion vans, the roll stop latch on the lift's outer barrier can bend or misalign until a wheelchair occupant can ride over it. The 2009-2010 model years have HVAC control knobs that can fracture and spin freely, preventing the driver from engaging the defroster and reducing windshield visibility. The 2003-2004 model years, particularly those registered in northern states, can develop significant corrosion in the fuel tank filler pipe that allows fuel to leak during refueling, creating a fire risk near any ignition source.
