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2002 Chevrolet Express

Owner reports · Recalls · Investigations

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There is not enough comparable history to draw a useful model-year comparison.

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Counts vary with age, sales and reporting. They are not failure rates.

What owners reported most

All reported categories

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When problems were reported

Mileage at the reported incident

41 reports with mileage · 14 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Service Brakes, Hydraulic. Review the 10 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 8 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine And Engine Cooling. Review the 8 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

0 crash reports3 fire reports0 injury reports

Electrical System complaints

8 reports
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7,000 miles · May 8, 2005
Electrical System

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 …

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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 ODI #10120222

14,628 miles · Apr 26, 2005
Electrical SystemFire

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…

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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 ODI #10118492

Mileage unknown · Mar 7, 2005
Electrical SystemEngine And Engine CoolingFuel System, Gasoline

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 SCRAPPIN…

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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 ODI #10114991

45,000 miles · Feb 28, 2005
Electrical SystemFire

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 ODI #10112265

51,000 miles · Aug 12, 2004
Electrical System

THE CONSUMER SAW BATTERY ACID LEAKING FROM THE VEHICLE. THE MECHANIC REPAIRED THE PROBLEM ONCE, HOWEVER THE PROBLEM RESURFACED. *JB THE POSITIVE BATTERY POST BROKE AND CAUSED THE ACID TO LEAK DOWN THE SIDE OF THE ENGINE COMPARTMENT. THE DEALER WOULD NOT PROVIDE ANY FINANCIAL ASSISTANCE AND TOLD THE CONSUMER TO CALL AC DELCO…

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THE CONSUMER SAW BATTERY ACID LEAKING FROM THE VEHICLE. THE MECHANIC REPAIRED THE PROBLEM ONCE, HOWEVER THE PROBLEM RESURFACED. *JB THE POSITIVE BATTERY POST BROKE AND CAUSED THE ACID TO LEAK DOWN THE SIDE OF THE ENGINE COMPARTMENT. THE DEALER WOULD NOT PROVIDE ANY FINANCIAL ASSISTANCE AND TOLD THE CONSUMER TO CALL AC DELCO. THE CONSUMER CONTACTED AC DELCO AND WAS TOLD IT WAS THE DEALER'S PROBLEM. *NM

NHTSA ODI #10080280

Mileage unknown · Aug 25, 2003
Electrical SystemExterior Lighting

CONSUMER NOTICED THAT WHEN HEADLIGHTS ARE TURNED ON TAIL LIGHTS FUSE BLOWS OUT INTERMITTENTLY.*AK

NHTSA ODI #10034504

15,542 miles · May 2, 2003
Electrical System

WHEN TAPPING THE GAS PEDAL LIGHTLY THE REDUCED ENGINE POWER AND SERVICE ENGINE SOON LIGHTS COME ON AND VEHICLE REMAINS RUNNING BUT LOOSES ALL POWER. *TT

NHTSA ODI #10016937

11,500 miles · Feb 6, 2003
Electrical SystemExterior LightingFire

2002 CHEVROLET EXPRESS VAN WITH EXPLORER CONVERSION - BURST INTO FLAMES WHILE IN OUR DRIVEWAY (ENGINE OFF). EXTENSIVE FIRE DAMAGE TO DRIVERS SIDE. EXTENSIVE SMOKE DAMAGE TO INTERIOR. FIRE MARSHALL STATES SMOKE PATTERN INDICATED FIRE ORIGONATED A BOTTOM OF DRIVER'S DOOR - LIGHT OR WIRING. OF NOTE, A "RECALL NOTICE" ARRIVED AT OUR…

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2002 CHEVROLET EXPRESS VAN WITH EXPLORER CONVERSION - BURST INTO FLAMES WHILE IN OUR DRIVEWAY (ENGINE OFF). EXTENSIVE FIRE DAMAGE TO DRIVERS SIDE. EXTENSIVE SMOKE DAMAGE TO INTERIOR. FIRE MARSHALL STATES SMOKE PATTERN INDICATED FIRE ORIGONATED A BOTTOM OF DRIVER'S DOOR - LIGHT OR WIRING. OF NOTE, A "RECALL NOTICE" ARRIVED AT OUR HOME IN THE MAIL FOR THE RUNNING BOARD LIGHT WIRING HARNESS ON 2/5/03 WHICH WAS "DATED" 1/23/03.

NHTSA ODI #10005390

Official recalls

0

No recalls in this snapshot.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

1

EA04012 · Hydraulic Pump Failres

Opened Apr 30, 2004 · Closed Feb 28, 2005

Status: closed (inferred from source dates) · Service Brakes, Hydraulic:power Assist; Steering:hydraulic Power Assist System

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.

Additional source detail variants (2)

Service Brakes, Hydraulic:power Assist

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.

Steering:hydraulic Power Assist System

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.