2002 Chevrolet Express Owner Complaints

The contact owns a 2002 Chevrolet Express. The contact stated while driving 65 MPH, she heard an abnormal loud banging sound coming from the rear end of the vehicle. The contact stated that the passenger’s side rear axle detached from the vehicle, causing the tire to detach and roll away. The contact did not sustain any injury. The vehicle was towed to a tow lot. The dealer and the manufacturer were not notified. The vehicle was not diagnosed nor repaired. The approximate failure mileage was 100,000.

NHTSA ID

11435043

Incident

Sep 29, 2021

Mileage

100,000 mi

THE SIDE HINGES SEIZE UP AND BREAK. IT THROWS THE DOOR ALIGNMENT OFF AND I AM NO LONGER ABLE TO COMPLETELY CLOSE THE FRONT SIDE DOOR AND IT KEEPS THE PASSENGER DOOR FROM OPENING ALSO. THIS IS A CONTINUEING PROBLEM CHEVROLET HAS WITH THEIR EXPRESS VANS. IT IS A DESIGN PROBLEM AND ALSO CHEAP MATERIALS CAUSED IT TO RUST AND SEIZE UP AND THEN BREAK THE HINGE, THE HINGE IS WELDED ON. VERY EXPENSIVE TO HAVE REPARED. IT IS DANGEROUS AS PEOPLE CAN NOT GET OUT OF THE VAN. CHEVROLET NEEDS TO OFFER AN INEXPENSIVE FIX FOR THIS.

NHTSA ID

11115830

Incident

Jul 1, 2018

Mileage

62,000 mi

WHEN I CAME OUTSIDE THE GLASS WAS BROKEN AND HAD BEEN THROWN TO THE OUTSIDE OF THE VEHICLE. THE VEHICLE HAD BEEN DRIVEN THE DAY BEFORE AND WAS FINE. IT WAS PARKED IN THE SHADE AND AWAY FROM ANYTHING WHICH COULD HAVE HIT IT. IT WAS LOCKED AND NOT TOUCHED IN ANY WAY. THE BROKEN FRAGMENTS WERE ON THE GROUND BELOW THE GLASS FRAME AREA. IT IS THE SAME TYPE OF GLASS THAT I SAW IN THE STORY ON THE NEWS YESTERDAY ABOUT THE SUN ROOFS THAT BREAK. WHEN I SAW THE STORY I KNEW THIS HAD TO BE THE EXPLANATION. I HAVE A PICTURE AND THE TEXT I SENT THAT DAY BECAUSE I WAS SO SHOCKED AT HOW SOMETHING LIKE THIS COULD HAPPEN, IT MADE NO SENSE. NOW IT MAKES PERFECT SENSE.

NHTSA ID

10747178

Incident

Jul 21, 2015

Mileage

130,000 mi

PASSLOCK SECURITY SYSTEM CONSTANTLY WON'T ALLOW VAN TO START. CHEVROLET SAYS TO HAVE THE SYSTEM "RELEARN THE KEY" BY WAITING FOR 10 MIN THEN TRYING TO START THE VEHICLE. IT SOMETIMES TAKES 3-4 TRIES OF DOING THIS BEFORE IT STARTS.

NHTSA ID

10538042

Incident

Aug 2, 2010

Mileage

125,000 mi

2002 CHEVY 2500 EXPRESS VAN. FAILURE OF POWER BOOSTER, LOST BOTH BRAKE POWER AS WELL AS STEERING POWER. ALMOST IMPOSSIBLE TO CONTROL CAR. REPLACED ONCE, FAILED AGAIN 6 MONTHS LATER. REPLACED AGAIN. FAILED AGAIN THIS YEAR. I AM NOW ON MY FORTH POWER BOOSTER, FAILURE IS VERY DANGEROUS AS YOU LOSE BOTH STEERING AND BRAKES AT SAME TIME. *TR

NHTSA ID

10313423

Incident

Nov 15, 2007

Mileage

108,000 mi

DRIVER'S SIDE REAR VIEW MIRROR VIBRATES EXCESSIVELY. HARD TO VIEW ITEMS ON THE MIRROR. *TR

NHTSA ID

10265946

Incident

Oct 31, 2002

Mileage

17,000 mi

TL*THE CONTACT OWNS A 2002 CHEVROLET EXPRESS. WHILE DRIVING 50 MPH, THE VEHICLE COMPLETELY SHUT OFF AND WOULD NOT RESTART. THE VEHICLE WAS TOWED TO THE DEALER AND THEY REPLACED THE FUEL FILTER, HOWEVER, THE FAILURE RECURRED. THE VEHICLE WAS THEN TOWED TO A GM DEALER, WHO REPLACED THE CRANK SENSOR. THE CONTACT STATED THAT THE VEHICLE IS CURRENTLY OPERATING NORMALLY. THE CURRENT MILEAGE WAS 16,612 AND FAILURE MILEAGE WAS 16,594.

NHTSA ID

10204751

Incident

Sep 25, 2007

Mileage

16,594 mi

INTAKE MANIFOLD GASKET FAILURE CAUSING ENGINE TO SEIZE AT 69,700 MILES. *TR

NHTSA ID

10200576

Incident

Aug 20, 2007

Mileage

69,700 mi

ONE OF THE HINGES TO THE DOUBLE SIDE DOORS ON THE FULL SIZE 2002 CHEVROLET EXPRESS BROKE OFF TODAY. *AK

NHTSA ID

10192947

Incident

Jun 11, 2006

Mileage

34,820 mi

BRAKES ON MY 2002 CHEVY EXPRESS VAN ARE NOT LARGE ENOUGH TO STOP VEHICLE WITHOUT WARPING ROTORS. THIS IN TURN CAUSES LONGER STOPPING DISTANCES AND A VIBRATION THAT CAUSES STEERING WHEEL TO PULSATE. *NM

NHTSA ID

10178688

Incident

Aug 10, 2004

REAR BRAKE LIGHTS DOES NOT LIGHT AT THE SAME TIME. THEY OPERATE LIKE A CAROUSEL. WHEN THE LIGHT SWITCH IS TURNED ON ONLY THE CENTER BRAKE LIGHT ILLUMINATES. *JB

NHTSA ID

10173187

Incident

Oct 31, 2006

Mileage

78,000 mi

THE REAR END WENT OUT AND THE ROTORS ARE WARPED. I HAD THE REAR END REPLACED AND THE SERVICE TECH SAID HE HAD NEVER SEEN ANYTHING LIKE THIS IN HIS HISTORY OF WORKING ON VEHICLES. I HAD JUST PURCHASED THE VAN JAN. 28TH AND IT HAD A 60 DAY WARRANTY. I HAD TAKEN IT BACK TO THE DEALERSHIP ON FEB 17TH AND REPORT THE NOISES IT WAS MAKING AND THEY IN TURN SAID NOTHING WAS WRONG. THE SERVICE TECH THAT REPLACED THE REAR END SAID IT COULD NOT HAVE BEEN MISSED BECAUSE THE DIFFERENTIAL WAS BENT COMPLETELY UP ON THE AXLES. HE SAID IT WAS DUE TO EITHER WHOEVER OWNED IT PREVIOUS HAD TOWED SOMETHING TO HEAVY OR THE THERE WAS A MANUFACTURER DEFECT IN THE DIFFERENTIAL. REGARDLESS HE DEALERSHIP (LAWRENCE MARSHALL) IN DENISON TX WILL NOT STAND BEHIND IT AND I AM OUT OF POCKET FOR THIS BIG EXPENSE. THEY OVER CHARGED ME FOR THE VEHICLE AND NOW THIS. I HAVE A BIG CONCERN BECAUSE THE NOISE IT WAS MAKING HAD STOPPED AFTER THE REAR END WAS REPLACED, BUT WHEN I WAS DRIVING IT TODAY IT CLUNKED TWO DIFFERENT TIMES, SAME NOISE AS BEFORE, SO NOW I AM WORRIED. I DON'T KNOW WHO TO TRUST TO HELP ME AS I HAVE BEEN RIPPED OFF SO BAD NOW. CAN YOU PLEASE HELP ME OR ADVISE ME WHERE I CAN HAVE THIS VEHICLE COMPLETELY CHECKED OUT. THE SERVICE TECH SAID IT WAS A MIRACLE THAT THE DRIVE SHAFT DID NOT FALL OUT ON THE TRIP MYSELF AND GRANDCHILDREN WERE ON. IT BROKE DOWN IN OHIO AND I LIVE IN OKLAHOMA SO OF COURSE IT SET ME BACK A LOT OF EXPENSE I COULD NOT AFFORD. I THOUGHT THE DEALERSHIP SHOULD STAND BEHIND THE 60 DAY WARRANTY SINCE I HAD TAKEN IT BACK TO THEM WITHIN THE WARRANTY TIME, BUT THEY HAVE GIVEN ME NOTHING BUT GRIEVE. I WOULD APPRECIATE ANY HELP I CAN GET AS I AM AFRAID OF THE VAN NOW. *JB

NHTSA ID

10157142

Incident

Apr 16, 2006

Mileage

56,500 mi

DT*: THE CONTACT STATED WHILE APPLYING BRAKE PRESSURE AT VARIOUS SPEEDS, THERE WAS A THUMPING NOISE FROM THE UNDERHOOD AREA FOLLOWED BY ABS ACTIVATION. THE CONTACT INSPECTED UNDERNEATH THE VEHICLE AND DETERMINED BRAKE FLUID WAS LEAKING FROM A BRAKE LINE. THE VEHICLE IS SCHEDULED FOR FURTHER INSPECTION AT THE DEALER.

NHTSA ID

10155134

Incident

Apr 12, 2006

Mileage

65,000 mi

2002 CHEVROLET CONVERSION VAN EXPRESS 1500 HAD A PROBLEM WITH THE DRIVERS SIDE WINDOW. EXPRESS WINDOW WOULD GO DOWN BUT NOT GO BACK UP. *TS THE MOTOR WAS REPLACED THREE TIMES, FINALLY THE SWITCH WAS REPLACED. THE BRAKES AND MASTER CYLINDER HAD TO BE REPLACED. THE CONSUMER WAS TOLD THE BRAKES WERE INSUFFICIENT FOR THE WEIGHT OF THE VEHICLE. THE MICHELIN TIRES ONLY LASTED 24,000 MILES. *JB

NHTSA ID

10155198

Incident

Jan 1, 1901

Mileage

47,000 mi

BRAKES WERE MAKING A "GRUMBLING NOISE". NOT THE TYPICAL SQUEAL OR GRINDING NOISE ASSOCIATED WITH BRAKES. WENT TO THE DEALER AND HE SAID THE FRONT DISC BRAKES WERE BADLY WORN. ONLY 32,000 MILES ON THE VEHICLE. NEVER, NEVER HAVE I EVER HAD TO REPLACE BRAKES WITH SUCH LOW MILEAGE. DRIVING FOR 45 YEARS AND NEVER HAD THIS HAPPEN. THEY FIXED IT, NOT UNDER WARRANTY, SO I PAID. NOW, WITH A YEAR ON THE NEW BRAKE LININGS, THEY ARE MAKING NOISE AGAIN. VERY DISTURBING. THE VEHICLE IS USED FOR WORK AND IS NOT ABUSED, I AM THE ONLY ONE THAT DRIVES IT. DRIVING VANS FOR 30 YEARS AND THIS IS VERY DISAPPOINTING. *JB

NHTSA ID

10153694

Incident

Mar 7, 2005

Mileage

32,000 mi

DT: THE CONTACT STATED WHILE DRIVING THE VEHICLE STALLED INTERMITTENTLY. THE VEHICLE STALLED WHEN SLOWING DOWN OR WHEN STOPPING. THE VEHICLE WAS TAKEN TO THE DEALERSHIP AND THE FUEL INJECTOR PUMP WAS REPLACED, THIS REPAIRED THE VEHICLE.*AK UPDATED 12/07/05. *JB UPDATED 12/7/2005. *NM

NHTSA ID

10142933

Incident

Sep 18, 2005

Mileage

64,216 mi

DT:THE CONTACT STATED THE LEFT REAR TIRE DEVELOPED A BULGE WITHIN THE TREAD. HE BROUGHT THE VEHICLE TO AN INDEPENDENT REPAIR SHOP, AND THEY REPLACED THE TIRE WITH A SPARE. WHEN HE RETURNED HOME THE VEHICLE WAS TAKEN TO A FIRESTONE DEALER, WHO DISCOVERED THERE WAS A COMPLETE BELT SEPARATION ON THAT TIRE. A SECOND INCIDENT LATER OCCURRED ON THE LEFT FRONT TIRE IN A SIMILAR FASHION. BOTH OF THE FAILED FIRESTONE TIRES WERE REPLACED WITH GOODYEAR TIRES. WHILE DRIVING THE RIGHT REAR REMAINING FIRESTONE TIRE BLEW OUT AT 75 MPH RESULTING IN DAMAGE TO THE VEHICLES FENDER AND BUMPER AREA. HE AVOIDED ANY COLLISION. HE TOOK PHOTOGRAPHS OF THE EXTENSIVE DAMAGE. NO FURTHER REPAIRS OR CORRECTIONS HAVE BEEN MADE AT THIS TIME. THIS IS A FIRESTONE STEELTEX R4S LT245/75/R16 LOAD RANGE E. THESE WERE THE ORIGINAL TIRES ON THE VEHICLE AT PURCHASE. *AK UPDATE 12/27/2005 - THE TIRES WERE MADE IN CANADA. *NM

NHTSA ID

10141543

Incident

Mar 27, 2005

Mileage

50,000 mi

CONSUMER 2002 CHEVROLET EXPRESS ENGINE ALMOST STALLED. CONSUMER HAD FUEL INJECTION SYSTEM CLEANED. *TS THE CONSUMER WAS TOLD THERE WAS CORROSION ON THE DISTRIBUTOR CAP AND ROTOR WHICH HAD ALREADY BEEN REPLACED TWICE. *JB

NHTSA ID

10142082

Incident

May 24, 2004

Mileage

19,752 mi

DT: 2002 CHEVROLET EXPRESS. THE CONTACT STATED THE SPARE TIRE IS SECURED BY STRAPS ,AND ONE OF THE STRAPS CAME OFF THE VEHICLE. THERE WAS NO ONE BEHIND THE CONTACT'S VEHICLE. THEREFORE, NO ONE WAS INJURED. THE SPARE TIRE HAD BEEN USED A YEAR AGO. THE MANUFACTURER STATED THIS HAPPENED REGULARLY. ALSO, THE TIRE CAME OFF AT THIS TIME AND THAT TIRE WAS LOST. THE CONTACT PURCHASED ANOTHER TIRE. IT WAS LOCATED IN THE BACK OF THE VEHICLE. *AK

NHTSA ID

10139406

Incident

Sep 15, 2005

SINCE THE 2002 CHEVROLET 1/2 TON CUSTOM VAN WAS PURCHASED IT HAS GIVEN ME BRAKE PROBLEMS. FIRST WAS THE ROTORS WHICH WAS SETTLED IN COURT, GENERAL MOTORS CUSTOMER SATISFACTION PROGRAM! THE BRAKES HAVE FAILED ABOUT 4 TIMES, 3 TIMES WITH ME AND ONCE WITH MY SON. THE STEERING ALSO GOES HARD. THE VAN WAS TAKEN TO THE CHEVROLET DEALERSHIP TO BE REPAIRED. THEY CLAIMED NOTHING WAS WRONG AND TO TAKE IT BACK. MY HUSBAND POINTED OUT THE NHTSA OFFICE OF DEFECTS INVESTIGATION 05V005000 BUT THEY COULD CARE LESS AND CLAIMED THEY LACK THE SKILL TO WORK ON BRAKE PROBLEMS. *NM

NHTSA ID

10138144

Incident

Sep 25, 2005

Mileage

35,000 mi

THE VEHICLE SHUTS DOWN WITHOUT WARNING WHILE DRIVING, FOUND A GM SERVICE BULLETIN STATING TO REPLACE THE DISTRIBUTOR CAP AND ROTOR BUT HAVE DONE THAT NOW 4 FOUR TIMES BUT THIS DOESN'T CORRECT THE CAUSE JUST THE EFFECT. TO DATE IT HAS REDENDERED OUR VEHICLE UNDRIVEIBLE DUE TO IT'S UNRELIBILITY. GM ISN'T DOING ANYTHING TO HELP US OUR OUR WHEELCHAIR BOUND SON WHO RELIES ON THIS VEHICLE FOR MEDICAL APPOINTMENTS.

NHTSA ID

10120222

Incident

Jan 10, 2005

Mileage

7,000 mi

VAN IS USED IN A MUNICIPAL PARKS AND RECREATION DEPARTMENT FOR MAINTENANCE DUTIES. OPERATOR STARTED VEHICLE AT BEGINNING OF DAY TO WARM UP. OPERATOR LEFT THE VEHICLE. OPERATOR RETURNED APPROXIMATELY FIVE MINUTES LATER AND SAW SMOKE COMING FROM INSIDE THE PASSENGER AREA. OPERATOR CALLED 911 AND RETRIEVED A DRY POWDER EXTINGUISHER. OPERATOR SAW FLAMES COMING FROM AN AREA IN THE REAR OF THE DRIVER'S SEAT. OPERATOR TURNED OFF IGNITION AND USED EXTINGUISHER ON THE FIRE, PUTTING IT OUT. INVESTIGATION SHOWS AREA OF ORIGIN TO INSIDE THE DRIVER?S SIDE SEAT BELT CHANNEL. PLASTIC MOLDING COVERS THIS CHANNEL. A WIRING HARNESS IS LOCATED IN THIS CHANNEL. HEAVIEST BURN OF THE HARNESS IS DIRECTLY AT THE CONNECTION OF THE HARNESS TO THE DRIVER?S SIDE SEAT BELT MECHANISM LOCATED AT THE FLOOR. FIRE PARTIALLY CONSUMED HARNESS AND PLASTIC MOLDING. THERE ARE PICTURES OF THE DAMAGE AND HARNESS. HARNESS WAS CUT BACK TO CLEAN WIRING ON BOTH SIDES OF DAMAGED SECTION AND IS AVAILABLE FOR INSPECTION.*AK

NHTSA ID

10118492

Incident

Mar 8, 2005

Mileage

14,628 mi

1 AFTER 70000 MILES, THE GROUND CONNECTION IN THE BRAKE LIGHT/TAILLIGHT SOCKET BECOMES OXIDIZED FROM HEATING UP. 2. THE BRAKE LIGHTS QUIT WORKING. 3. I REMOVED A PLASTIC CLIP FROM THE BULB SOCKET AND ALLOWED THE GROUND WIRE TO ACQUIRE A NEW CONNECTION. 2002 CHEV EXPRESS VANPOOL VANS AT HILL AIR FORCE BASE, UTAH. *AK

NHTSA ID

10116592

Incident

Apr 2, 2005

Mileage

70,000 mi

2002 CHEVROLET EXPRESS ENGINE LOST POWER AND REAR BRAKES CAUGHT ON FAILED. *BF THE CONVERTER WAS CLOGGED WHICH RESULTED IN THE ENGINE LOSING POWER. THE CHECK SERVICE ENGINE SOON LIGHT ILLUMINATED AND THE ENGINE MISSED ON ACCELERATION. THE DEALER REPLACED THE PLUG WIRE CAP ROTOR AND DISTRIBUTOR. THE CONSUMER HEARD A SCRAPPING NOISE COMING FROM THE REAR BRAKES AND VEHICLE SHOOK WHILE BRAKING. THERE WAS VIBRATION IN THE DRIVELINE ON ACCELERATION, THE BELT WAS REPLACED. VEHICLE CONSUMED EXCESSIVE AMOUNTS OF OIL. FLUID LEAKED FROM REAR AXLE, DEALER REPLACED THE REAR AXLE SEALS. THE DEALER REPLACED THE FUEL SENDER ASSEMBLY DUE TO STALLING. THE VEHICLE BATTERY WENT DEAD AFTER THE VEHICLE SAT OVERNIGHT. CLUTCH WAS LOUD AND PROVIDED NO POWER ON HOT DAYS, THE CLUTCH FAN WAS REPLACED. THE CONSUMER REQUEST THAT THE MANUFACTURER PROVIDE A REPLACEMENT VEHICLE OR REFUND THE FULL CONTRACT PRICE PLUS INCIDENTAL COST. *NM

NHTSA ID

10114991

Incident

Dec 6, 2004

VEHICLE WOULD NOT START. WENT INSIDE TO CALL TOW TRUCK TO HAVE IT TOWED TO MECHANIC. TURNED AROUND AND IT WAS ON FIRE. VEHICLE WAS NOT RUNNING;PARKED.

NHTSA ID

10112265

Incident

Feb 21, 2005

Mileage

45,000 mi