Model year record
2002 Chevrolet Express recalls & problems
The 2002 Chevrolet Express has no safety recalls on file with NHTSA, and 56 owner complaints. The most-reported problem area is service brakes, hydraulic (11 complaints).
Safety recalls
No safety recalls have been filed for the 2002 Chevrolet Express.
Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.
Crash test ratings
2002 Chevrolet Express Van
| Frontal crash | Not Rated |
|---|---|
| Side crash | Not Rated |
| Rollover | Not Rated |
NHTSA 5-Star Safety Ratings (New Car Assessment Program). Ratings are comparable only between vehicles of similar size and weight, and ratings from 2011 on use tougher tests than earlier years. Photos: NHTSA.
Fuel economy
Express 1500/2500 2WD
| City / highway | 13 / 17 mpg |
|---|---|
| Fuel | Regular Gasoline |
5 L · 8 cyl · Automatic 4-spd · Rear-Wheel Drive · about $4,450/year to fuel
Express 1500/2500 2WD
| City / highway | 13 / 16 mpg |
|---|---|
| Fuel | Regular Gasoline |
4.3 L · 6 cyl · Automatic 4-spd · Rear-Wheel Drive · about $4,800/year to fuel
Express 1500/2500 2WD
| City / highway | 12 / 16 mpg |
|---|---|
| Fuel | Regular Gasoline |
5.7 L · 8 cyl · Automatic 4-spd · Rear-Wheel Drive · about $4,800/year to fuel
EPA estimates from fueleconomy.gov for each engine and transmission sold. Annual cost is the EPA's estimate for 15,000 miles a year at its current fuel and electricity price assumptions. Your results will vary.
What owners report
| Problem area | Complaints | Typical mileage* |
|---|---|---|
| Service brakes, hydraulicFoundation components › Disc; Foundation components › Disc › Rotor | 11 | 35,000 mi |
| Electrical systemWiring; 12v/24v/48v battery | 9 | 15,542 mi |
| StructureFrame and members; Body › Door | 8 | 48,410 mi |
| Power trainAxle assembly; Driveline › Differential unit | 8 | 56,500 mi |
| Engine and engine coolingEngine; Engine › Gasoline | 8 | 19,752 mi |
| TiresTread/belt; Sidewall | 7 | 20,000 mi |
| Fuel system, gasolineFuel injection system; Storage › Tank assembly | 6 | — |
| Exterior lightingBrake lights; Headlights | 6 | 40,750 mi |
| SteeringGear box (other than rack and pinion) | 4 | 30,000 mi |
| SuspensionFront › Wheel bearing; Front | 4 | 34,500 mi |
| VisibilityPower window devices and controls; Rearview mirrors/devices | 2 | — |
| Unknown or other | 2 | — |
*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.
Recent owner complaints
- Electrical system › Instrument panel › Speedometer/odometer
Odometer Fraud. The contact purchased a 2002 Chevrolet Express. It was discovered that there was a mileage discrepancy. The vehicle was a private sale. At the time of purchase, the mileage was 180,000. It was later discovered through a diagnostic test that the mileage was 298,000. The seller was contacted and informed the contact that the instrument cluster was potentially tampered with by a previous seller. The seller denied a refund request due to an as-is sale and directed the contact to the NHTSA Hotline.
- Suspension
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 passengerâs 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.
- Structure › Body
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.
- Structure › Body
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.
- Unknown or other
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.
- Service brakes, hydraulic
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
- Visibility › Rearview mirrors/devices
DRIVER'S SIDE REAR VIEW MIRROR VIBRATES EXCESSIVELY. HARD TO VIEW ITEMS ON THE MIRROR. *TR
- Engine and engine cooling
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.
Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.
NHTSA defect investigations
- HYDRAULIC PUMP FAILRESClosedLed to recall 05V005000
GM IS CONDUCTING A RECALL ON ALL SUBJECT VEHICLES BUILD BETWEEN MAY 1999 AND OCTOBER 14, 1999.SIGNIFICANT CHANGES WERE INCORPORATED INTO PRODUCTION IN EARLY OCTOBER 1999, AND VEHICLES BUILT AFTER THAT DATE HAVE LOWER WARRANTY FAILURE RATES.THE COMPLAINT AND WARRANTY DATA APPEAR TO SUPPORT THE EFFECTIVENESS OF THESE CHANGES. GM MADE ADDITIONAL CHANGES IN NOVEMBER 1999, FEBRUARY 2000, MAY 2001, AND FEBRUARY 2004.ODI WILL CONTINUE TO MONITOR THIS PROBLEM AND WILL TAKE FURTHER ACTION, IF WARRANTED, IN THE FUTURE.FOR FURTHER TECHNICAL DETAILS SEE THE ATTACHED ENGINEERING ANALYSIS REPORT.