Body complaints by model year
| Year | Complaints | Share of year's complaints | Typical mileage |
|---|---|---|---|
| 2021 | 2 | 15% | — |
| 2020 | 3 | 18% | 1,000 miles |
| 2018 | 1 | 9% | — |
| 2016 | 3 | 20% | 2,000 miles |
| 2015 | 1 | 13% | 26,000 miles |
| 2012 | 1 | 8% | 15,000 miles |
| 2011 | 1 | 8% | 94,000 miles |
| 2010 | 1 | 7% | 101,000 miles |
| 2009 | 1 | 10% | — |
| 2008 | 1 | 7% | 0 miles |
| 2007 | 1 | 6% | 60,000 miles |
| 2006 | 1 | 8% | 63,000 miles |
| 2005 | 5 | 22% | 89,000 miles |
| 2004 | 2 | 10% | 150,000 miles |
| 2003 | 5 | 8% | 228,000 miles |
| 2002 | 8 | 14% | 62,000 miles |
| 2001 | 2 | 4% | — |
| 2000 | 7 | 8% | 115,000 miles |
| 1999 | 6 | 9% | 77,000 miles |
| 1998 | 3 | 13% | 80,000 miles |
| 1997 | 3 | 10% | 200,000 miles |
Which parts fail
Components named in complaints (doors, hood, frame, rust, paint and trim).
Mileage when the problem started
What owners report
The contact owns a 2021 Jayco Redhawk. The contact stated that while inspecting underneath the RV the plumbing hoses and lines as well electrical wires, fuel line from the propane tank, and fuel line from the generator was just lying on the frame. The hoses and lines were not insulated or secured underneath the RV. The contact stated that he was concerned that a fire could have been started. The contact stated that he wire-tied all the wires, so they were not laying on the frame. The vehicle was taken to the dealer who only secured the wires with a single wire tie. The contact stated that many of the wires were still just hanging as the dealer did not repair the problem. The contact stated that the brake, fuel, and electrical harness were all clamped together which could cause a failure. The Jayco dealer advised the contact to take the vehicle to a GM dealer for repairs to the chassis. …
Bought this van new & when traveling down a hill, brake assist helps slow up the van. Once the van is on level ground, it will NOT shift back out of the brake assist & it takes effort or time to return to normal D. I was told I must set up & find a hill. I had major water leaks in the van & once corrected, there started a whistling of air now. The passenger door was 1/4" off, nowhere near flush. How does that get missed? Lastly, the right read brake cylinder went out with less then 12,000 miles on it. Many many problems with this "new" van. I'm concerned for my safely & others. The future looks bad with this lemon.
Tl* the contact owns a 2016 Chevrolet Express. The contact stated that water was leaking from the driver's side visor connection. Water also leaked onto the contact and the floor. The instrument panel was also leaking. There were no warning indicators illuminated. The vehicle was taken to sawyer Chevrolet (351 w bridge st, catskill, ny 12414, [phone]) where it was diagnosed that a new wi-fi antenna gasket needed to be installed. The vehicle was repaired, but failed again days later. The manufacturer was notified and did not assist. The failure mileage was 36,000.
Tl* the contact owns a 2016 Chevrolet Express. The contact stated that when the vehicle was parked on an incline and the sliding door was opened, there was no locking mechanism to prohibit the sliding door from closing independently. The contact stated that on several occasions the door closed independently while an employee was making deliveries with the vehicle. The manufacturer was notified of the failure and the contact was informed by the general motors fleet coordinator that the vehicle was operating as intended. The approximate failure mileage was 300.
Paint is peeling from ALL parts of the exterior vehicle, even around the window frames and door frames! It appears that NO PAINT PRIMER was used, at all! My white van has missing paint from about 75% of the vehicle, with bubbling going on, in the remainder of paint that has yet to fall off! Looking at ANY Chevy van that is on the roadways, one can easily see that the paint has also been falling off those vehicles, as well! This is a well-known defect in the painting practices of most ALL Chevrolet Vans, and should be dealt with on a class-action basis, since all Chevrolet Van owners are forced to live with an inferior paint scheme on these vehicles! But new owners are not aware of these shortcomings, until they see the paint fall off their vans, for no apparent reason! And it is clearly seen that NO PAINT PRIMER was used, when you look at the paint chip that fell off! …
2005 Chevrolet Express shock tower failure. Consumer stated that the shock tower cracked in half. Was repaired. She states that the vehicle developed a shimmy after the repair. When the consumer took the vehicle to the shop for the shimmy, she was informed the tie rods had worn out and the technician stated that excessive weight and the wrong wheel/tire size caused additional stress and wear and tear on the vehicle. The ABS light flickered.
Tl* the contact owns a 2003 Chevrolet Express. The contact stated that the cable that held the seat belts together, located in the rear middle row, snapped without warning. As a result, the contact was concerned that, in the event of a crash, the seat belts would not secure properly and cause an injury. The contact also stated that the rear driver and passenger side door hinges fractured. The contact stated that the doors were glued shut. The dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failures. The failure mileage was 228,000. Updated 10/17 updated 10/4/18
During a family outing we were unable to close the right rear passenger door. Experienced difficulty closing door. After several attempts, I noticed the door was not aligned with the body of the car which prohibited the door latch to connect and close. The door would not close shut completely and has since knocked while driving and also creates a safety hazard for children & adults because it is primary exit for the rear exit to the sidewalk forcing passengers to exit from the rear left door passenger door onto the street to oncoming traffic that can lead to accident, bodily injury or fatality. No prior maintenance instructions or suggested upkeep was documented in the buyers manual which came with the vehicle that would indicate possible hinge corrosion or rusting. …
Related recalls (1)
Structure › Body › Door
General Motors LLC (GM) is recalling certain 2025 Chevrolet Express and GMC Savana vans. The impact beam located in the driver's side door may have improper welds.
Remedy: Dealers will replace the driver's side door, free of charge. Owner notification letters were mailed March 3, 2025. Owners may contact Chevrolet customer service at 800-222-1020 or GMC customer service at 800-462-8782.
Frequently asked questions
Which Chevrolet Express years have body problems?
By NHTSA complaints, the 2002 (8), 2000 (7), 1999 (6), 2003 (5) and 2005 (5) model years. Body complaints make up 14% of all complaints for the 2002.
Is there a recall for Chevrolet Express body problems?
Yes — 1 recall, including 25V-087 (door, Feb 13, 2025). Recall repairs are free at authorized dealers; check a specific car with the VIN recall check.
At what mileage do Chevrolet Express body problems start?
Across all years, half of the complaints with a recorded mileage happened before about 84,000 miles; 38% happened before 50,000 miles.
What part fails most often?
Owners most often name the body (25 mentions), followed by the body › door › hinge and attachments (16).
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.