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Print this page Notes: The Chevy Express is mechanically identical to the GMC Savana.


hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
116,555 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2003 Chevrolet Express fuel system problems

fuel system problem

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2003 Chevrolet Express Owner Comments

problem #11

Dec 212015


  • 124,000 miles


Corroded and leaking fuel filler neck. Foolish design involving dissimilar metals held in contact and surrounded with a conduit which holds water and road salt. Design is destined for failure. GM has a partial recall for the snow belt. Such a foolish design should be fixed everywhere as it is just a matter of time until failure.

- Prescott, AZ, USA

problem #10

Dec 032014

Express 8-cyl

  • 72,000 miles
I received a notice from GM ( doc id #32202443, #12167 fuel filler pipe corrosion) stating that there was a recall on my vehicle for leaking gasoline. I brought it to sighn Chevrolet in riverside ca and the service manager told me that ca vehicles do not qualify. I contacted customer complaints case # [xxx] and all they did was call the same service manager and got back to me saying they won't fix it. I believe I am driving around with a vehicle leaking gas on the road creating an extremely dangerous situation for my family with a dire fire hazard. My contention is, why would they send me a recall notice and then tell me I don't qualify? I did receive the notice and it said it had to be acted on before 12/31/12 but it was not leaking then. I don't care when it expires. It is a admitted defect and GM should stand behind their dangerous errors. Information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- Norco, CA, USA

problem #9

Aug 072014


  • 153,500 miles
The contact owns a 2003 Chevrolet Express. The contact stated that there was a fuel leak coming from the vehicle. The contact indicated that after refueling, fuel puddle under the vehicle. The vehicle was taken to an authorized dealer who diagnosed that the filler neck needed to be replaced and the metal fuel filler pipe was corroded. The contact was not included in NHTSA campaign id number: 12V388000 (fuel system, gasoline). The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 153,500.

- Jupiter, FL, USA

problem #8

Jul 012014


  • 107,000 miles


The contact owns a 2003 Chevrolet Express 1500 van. The contact stated that when fueling the vehicle, fuel sprayed from the filler neck. The dealer diagnosed that fuel filler pipe needed to be replaced. The vehicle had not been repaired. The manufacturer had not been notified. The approximate failure mileage was 107,000.

- West Jordan , UT, USA

problem #7

Sep 012003

Express 8-cyl

  • miles
This vehicle was bought brand new but unbeknownst to me was made in Canada (something which would not have been acceptable to me had I been told). Upon possession the windshield molding came off on the ride home. The driver side tierod end went at 12,000 miles and again at 24,000 miles because upon inspection the ball joints were never properly tightened. The bolts on the transmission were found by the dealer to have been never properly tightened. The sidedoor hinge had to be replaced at a cost of $600 because it froze up and could not be opened. The power steering unit rusted out at 12,000 miles and started leaking fluid and, what I find most important, I am not sure if I have airbags because the airbag light stays on but is noted to go off when the key is partially turned however the key cannot stay in this position and must be turned to start the vehicle. Fuel expectation was never near what I was told it would be and tailpipe consistently showed evidence of being blackened due to insufficient fuel burning. The poor backdoor design makes it difficult to see out the back window and it is clearly evident by almost every van of this type having a dented bumper due to this blindspot in design. I have not begun to list all the things not right with this vehicle but I will chalk them up to downright lying and just inferior parts and craftsmenship. This vehicle has been a nightmare.

- Columbiaville, MI, USA

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problem #6

Nov 152012


  • 148,000 miles
The contact owns a 2003 Chevrolet Express 1500. The contact stated that fuel was leaking from under the vehicle. The vehicle was taken to the dealer and to an independent mechanic for diagnostic testing. The technician and the mechanic advised that the return and delivery fuel lines would have to be replaced due to corrosion. The vehicle was not repaired. The approximate failure mileage was 148,000.

- Fruita, CO, USA

problem #5

Oct 172012


  • 126,600 miles


The contact owns a 2003 Chevrolet Express. The contact stated that she noticed a leak under the vehicle when she would put refuel. The vehicle was taken to a dealer for inspection where they advised that the fuel filler needed to be replaced. The vehicle was not repaired. The manufacturer was notified and stated that they would pay a portion of the repair costs. The failure mileage was 126,600.

- Ashburn, VA, USA

problem #4

Jul 022012

Express 8-cyl

  • 151,000 miles
When the vehicle fuel tank is filled, gas fumes are detected and some fuel can be seen on the bottom of the tank (a few drops of fuel). As the tank contents lower the smell and leak goes away. An access hole on the side of the van reveals that the tank has a small leak where the plastic fill neck was bonded to the tank. The steel fill neck and rubber connection look fine. This is a conversion van w/O a left hand door. This vehicle was bought from a southern climate area and is only recently been brought to a northern climate so corrosion is not suspected. Since I see no recall or many complaints, I am looking to repair or replace the tank. Currently looking for a seal material that could be applied to the leak and that works on polyurethane and resists fuel. Have not found one. The vehicle is well out of warranty but this does seem to present a safety issue. Short term solution is to not fill the tank.

- Grand Blanc, MI, USA

problem #3

Aug 172011


  • 111,000 miles
The contact owns a 2003 Chevrolet Express. The contact stated that a small amount of fuel continuously leaked out of the fuel tank filler neck immediately after refueling. The vehicle was taken to an independent mechanic who stated that the fuel filler neck tube exhibited rust corrosion. The part was replaced. The manufacturer was made aware of the problem. There was a recall associated with NHTSA campaign id number 12V388000 (fuel system, gasoline:storage:tank assembly: Filler pipe and cap) however the VIN was not included. The approximate failure mileage was 111,000.

- Burke, VA, USA

problem #2

Aug 142012


  • 127,000 miles
The contact owns a 2003 Chevrolet Express conversion van. The contact stated that while the vehicle was parked, he noticed a hole in the fuel filler neck. The vehicle was not taken to the dealer. The manufacturer was not contacted. The failure and current mileages were 127,000.

- Fredricksburg, VA, USA

problem #1

May 012012

Express 6-cyl

  • 162,000 miles
On a few occasions prior to locating a leak, I noticed a gasoline smell. Finally when filling earlier this month, I saw a lot of leaking coming out of the fuel filler tube, between the metal tube and the plastic cover surrounding the tube. When I got home, I cut off the plastic tube about halfway and found a static wire running the length of the tube. Everywhere, where this wire touched to metal pipe, it was corroded completely through. The static wire is of a different material and was not corroded. Presently I have wrapped the tube with a gasoline resistant tape. But, I will have to replace the tube soon. The local dealership has quoted approx. $241 without installation. Are there other instances like this and is there a recall I'm not aware of. Thank you for your time.

- Beaufort, SC, USA

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