NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
55 reports100,000 miles · Sep 30, 2021
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 passenger’s side rear axle detached from the vehicle, causing the tire to detach and roll away. The contact did not sustain any injury. …
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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 ODI #11435043
62,000 miles · Aug 5, 2018
Structure
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 …
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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 ODI #11115830
130,000 miles · Aug 8, 2015
StructureUnknown Or OtherVisibility/wiper
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 AR…
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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 ODI #10747178
125,000 miles · Aug 30, 2013
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.
NHTSA ODI #10538042
108,000 miles · Feb 23, 2010
Service Brakes, HydraulicSteering
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 SAM…
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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 ODI #10313423
17,000 miles · Apr 18, 2009
Visibility
DRIVER'S SIDE REAR VIEW MIRROR VIBRATES EXCESSIVELY. HARD TO VIEW ITEMS ON THE MIRROR. *TR
NHTSA ODI #10265946
16,594 miles · Oct 3, 2007
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…
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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 ODI #10204751
69,700 miles · Aug 23, 2007
Engine And Engine Cooling
INTAKE MANIFOLD GASKET FAILURE CAUSING ENGINE TO SEIZE AT 69,700 MILES. *TR
NHTSA ODI #10200576
34,820 miles · Jun 11, 2007
Structure
ONE OF THE HINGES TO THE DOUBLE SIDE DOORS ON THE FULL SIZE 2002 CHEVROLET EXPRESS BROKE OFF TODAY. *AK
NHTSA ODI #10192947
Mileage unknown · Jan 15, 2007
Service Brakes, Hydraulic
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 ODI #10178688
Illustration