Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

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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:
59,629 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

Mar 312012

Express 8-cyl

  • miles


For sometime, there was a smell of gasoline when filling this van, which I just attributed to a vapor release when the tank was full. Recently, I notice gas leaking under the van when filling at the gas station. The gas leaks in and around the brake lines. This van is a 2003 Chevrolet Express 1500 with left hand door option. This is my family vehicle and in researching this problem further, I understand it to be a known problem and a design flaw, where the fuel fill hose rusts. This needs a recall with immediate attention.

- Upper Darby, PA, USA

problem #10

Jan 192012

Express 8-cyl

  • miles
I was refueling my van and gas started pouring out from the bottom. After looking I discovered the fuel filler neck was rusted thru. The van only has 64K miles. I replaced it myself at this time. There was no collision damage....simply heavy corrosion.

- Indianapolis, IN, USA

problem #9

Sep 012011

Express 8-cyl

  • Automatic transmission
  • 64,000 miles
The contact owns a 2003 Chevrolet Express 1500. The contact stated that after refueling, he noticed an overpowering fuel odor. The contact further inspected the vehicle and found that the fuel tank was leaking and rusted. The vehicle was inspected by the dealer and they advised the contact that the gasoline filler tube needed to be replaced. The vehicle was not repaired. The manufacturer was contacted and they offered no assistance. The failure mileage was approximately 64,000. Updated 02/13/12

- East Pointe, MI, USA

problem #8

Dec 262011

Express 8-cyl

  • miles


2003 Chevrolet Express fuel filler pipe leak: Gas filler tube rusted through and gasoline leaked every time I refueled. Corrosion holes caused fuel to leak and creating a fire hazard. This van has a left side rear cargo door. This is a similar complaint as: ODI id number : 10413214

- Saline, MI, USA

problem #7

Jun 102011

Express 8-cyl

  • 51,459 miles
Gas leaking from fuel filler pipe onto inside of wheel well and ground. Examination reveals design of pipe assembly (metal pipe inside corrugated plastic tube), traps condensation and water around metal pipe guaranteeing rust and leaks. May be worse in high humidity regions but same assembly is open to water splashed up from road. This may only occur on cargo vans with left hand door option. Updated 08/11/11

- Arlington, VA, USA

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problem #6

Jul 102010

Express 8-cyl

  • 63,000 miles
Gas filler tube rusted through and gasoline leaked every time I refueled. This was not a small hole. The metal on the whole tube broke down causing fuel to leak and creating a fire hazard. Updated 08/11/11 updated 3/08/2012

- Arlington Heights, IL, USA

problem #5

Jun 202011

Express 8-cyl

  • 140,000 miles


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.

- Linden, MI, USA

problem #4

Sep 132010


  • 63,000 miles
Chevy 2003 express van fuel filler neck has rusted through in 2 places and gas pours out every time I refuel. Only 63,000 miles on van. I believe this I S a very serious fire hazard!!! is there a recall?

- Arlington Heights, IL, USA

problem #3

Sep 032010

Express 8-cyl

  • 92,464 miles
Fuel leaking from fuel tank filler tube when filling gas tank.

- Cherry Valley, IL, USA

problem #2

Aug 132010


  • 120,000 miles
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 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. The dealership simply indicated they never seen this on the express. It appears this is more than an isolated occurrence.

- Ypsilanti, MI, USA

problem #1

Oct 242008


  • 62,000 miles
Since October of 08, I ordered a filler tube which allows the gas to travel from the gas cap to the gas storage tank. Everytime I fill up, gas stations will shut the pump off due to severe leaking from this filler tube. The leak is so severe that the fear is somebody dropping a cigarette at the time of fillup. Approx 1 gal of gas leaks/ fillup. I ordered the new part in late October from the dealership I purchased my 2003 Chevy passenger Express van. I have spoken to the Chevy regional office and been told that the part is only available at 5 dealerships in the country but they have been reserved for customers and I would have to wait until the part gets manufactured once again. When" they don't know. I requested a similar vehicle be loaned to me until the new part becomes available. They said "no, if you feel unsafe then I shouldn't drive it. I told them this is an accident waiting to happen and it will not only cost my life but anyone in proximity to the gas station. One particular dealership shared with me that if GM doesn't pay a bill for whatever reason, the part manufacturer halts production and this is what happens. Will you please help me"

- Beachwood, OH, USA

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