Most common 2003 Chevrolet Express 2500 problems
Share of the 12 complaints; one complaint can involve more than one system. "~" is the median mileage when the problem started.
Chevrolet Express 2500 complaints by model year
Best Express 2500 years: 2004. Compare all years →
NHTSA defect investigations
Federal safety investigators have looked into a possible defect involving the 2003 Chevrolet Express 2500:
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,…
What 2003 Chevrolet Express 2500 owners say
Brakes
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. …
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).
Fuel & propulsion system
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. …
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.
Frequently asked questions
Is the 2003 Chevrolet Express 2500 a good car?
Based on 12 owner complaints filed with NHTSA, the 2003 Express 2500 rates average: 1.3× as many complaints as a typical year of the Express 2500 at the same age. Complaint counts don't account for sales volume or individual maintenance, so have any used car inspected before buying.
What is the most common problem with the 2003 Chevrolet Express 2500?
The brakes — 5 complaints, 42% of all complaints for this model year, most often about antilock/traction control/electronic limited slip. Next are the fuel & propulsion system (3) and body & structure (2).
How many recalls does the 2003 Chevrolet Express 2500 have?
NHTSA lists no recalls for the 2003 Chevrolet Express 2500. You can still confirm with your VIN using our VIN recall check.
What are the best and worst years of the Chevrolet Express 2500?
The best years by complaints, compared at the same age, are 2004. See the full Chevrolet Express 2500 years comparison.
At what mileage do 2003 Chevrolet Express 2500 problems happen?
The median mileage reported in complaints is about 83,000 miles; 30% of problems with a recorded mileage started before 50,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.