Chevrolet Express Recalls

The Chevrolet Express has 27 recalls spanning the 2003 through 2026 model years, with the most serious recent issues being a steering gear nut that can loosen and separate on 2025-2026 models, causing complete loss of steering control, and a gear shifter on 2026 models that can misreport the selected gear and allow unexpected vehicle movement.

The 2025 and 2026 model years carry several additional safety concerns. On 2025 cutaway and certain 2025-2026 cutaway chassis variants, tire sidewall damage from manufacturing can cause sudden air loss and loss of control. The 2025 model also has a driver's side door impact beam with improper welds that may not protect occupants in a side impact, and a front passenger head restraint that can break loose from the seat frame in a crash. On 2022-2023 models, transmission control software can cause harsh shifting, sudden deceleration, rear wheel lockup, or movement in an unintended direction. The 2021 model year, when equipped with a 6.6L gasoline engine, has a positive battery cable that can contact a fuse block post and cause a short circuit leading to a fire.

The 2019 model has a rear-quarter window compliance issue that also appears in 2016-2018 production: tempered glass was used instead of laminated glass in one or both rear-quarter windows, which can shatter and increase the chance of occupant ejection in a side impact or rollover. The 2018-2021 model years have an overcured tire defect where the sidewall can crack or the tread belt can separate. On 2016-2018 models, the rear climate control module can overheat if set to maximum heat or full floor vent while experiencing an electrical short, with the heat spreading into the headliner. The 2014-2017 power window switch on the driver's door can accumulate moisture, corrode internally, and create a fire risk from electrical resistance. Going back to 2016-2019, some cargo and cutaway vans left the factory without an interior rearview mirror or with a backup monitor that can display a mirror-reversed image, causing drivers to steer the wrong way when reversing.

On 2011-2014 compressed natural gas variants, the high-pressure regulator can leak natural gas, raising the risk of fire or explosion near any ignition source. A separate 2011 CNG conversion issue involves a vent pipe that, if improperly assembled when the pressure relief device activates, can vent natural gas directly into the passenger compartment. The 2013 model has an ignition switch that can release the key while the engine is still running or the transmission is out of Park, allowing the vehicle to roll away. The 2010 model has a voltage regulator inside the generator that can develop a short and generate enough heat to start an engine compartment fire. The 2009-2010 model years have HVAC control knobs that can fracture and spin freely on their shafts, potentially disabling the defroster and reducing visibility in cold or wet conditions. The 2003-2004 model years, particularly those registered in northern salt-belt states and equipped with a left side cargo door, can develop severe fuel filler pipe corrosion that allows fuel to leak during refueling near a potential ignition source.