CHEVROLET EXPRESS · model year

1996 CHEVROLET EXPRESS

20 NHTSA complaints, 1 crash report for this specific cohort.

NHTSA overall rating

Not crash-tested

New Car Assessment Program

The 1996CHEVROLETEXPRESS carries 20 consumer safety complaints in NHTSA's Office of Defects Investigation database for this specific model-year cohort. Within that volume, owners reported 1 crash, 3 fires, 0 injuries, and 0 fatalities. No NCAP 5-star crash-test rating is available for this model year in the federal database.

Component-level analysis is where model-year complaints become actionable: the top complaint category for the 1996 EXPRESS is service brakes, hydraulic:antilock/traction control/electronic limited slip with 2 filings, followed by steering:hydraulic power assist:pump (2) and fuel system, gasoline:delivery:fuel pump (2). Concentration in one or two component groups is the classic signature of a systemic defect; a flat distribution usually reflects normal aging, warranty complaints, or isolated build-plant variability.

NHTSA currently has 57 investigation files overlapping the 1996 EXPRESS, and 2 remain open. Owners comparing this cohort against neighboring years should pair the counters above with the complaint-by-year trend on the parent model page, a spike in a single year often tracks to a platform refresh, a new transmission supplier, or an updated ECU calibration. Use the related-complaint feed below to read raw owner narratives before deciding whether any pattern here affects your specific use case.

20
Complaints
1
Crashes
3
Fires
0
Injuries
0
Deaths

Total Complaints

20 filings

Crashes Reported

1 reports

Source

NHTSA ODI

Federal complaints database

Complaints vs. fleet median (215)

At or below the fleet median complaint volume.

Complaints by Component

ComponentCount
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP2
STEERING:HYDRAULIC POWER ASSIST:PUMP2
FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP2
FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY1
ELECTRICAL SYSTEM:WIRING:INTERIOR/UNDER DASH1
VISIBILITY:REARVIEW MIRRORS/DEVICES1
EQUIPMENT:APPLIANCE:AIR CONDITIONER1
ENGINE AND ENGINE COOLING:ENGINE:DIESEL1
ELECTRICAL SYSTEM:IGNITION:MODULE1
AIR BAGS:FRONTAL1
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL1
FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP1
STEERING:GEAR BOX (OTHER THAN RACK AND PINION)1
EQUIPMENT:MECHANICAL:CARRIER/RACK1
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM1

Recent Complaints

20030428FireELECTRICAL SYSTEM

THE HORN RELAY WAS SMOKING AND MELTED THE RELAY PANEL IT WAS MOUNTED TO. MORA FIRE DEPARTMENT WAS CALLED. THEY DISCONNECTED THE BATTERY. THE RELAY AND FUSE HAVE BEEN REMOVED AS A TEMPORARY FIX UNTIL A DEALER CAN INSTALL A NEW RELAY PANEL AND FIND THE PROBLEM. THIS GAVE NO WARNING SIGNS. THE VAN HAD BEEN TURNED OFF SINCE 12:20 PM. THE HORN WAS SILENT AT 2:00 PM WHEN MY WIFE BROUGHT SOMETHING IN FROM THE REAR COMPARTMENT OF THE VAN. AT AROUND 3:10 PM MY WIFE NOTICED THE HORN SOUNDING AND WENT TO CHECK IT OUT. SHE NOTICED SMOKE FROM DRIVER'S SIDE COMING OUT FROM UNDER THE HOOD. SHE OPENED THE HOOD AND NOTICED THE BATTERY WAS ALSO STARTING TO SMOKE. SHE DIALED THE SHERIFF'S OFFICE DISPATCHER TO GET THE FIRE DEPARTMENT ON THE SCENE. THE FIRE DEPARTMENT DISCONNECTED THE BATTERY AND STAYED AFTERWARDS TO ENSURE NO HOT EMBERS EXISTED. *AK ----DIMS 11 IVOQ ENTRY POSTED AFTER 12/12/02 CUT-OVER TO ARTEMIS-----751677.

Mileage: 58,500

20030120FirePOWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER

WE WERE ON OUR WAY TO FLORIDA WHEN WE STARTED SMELLING SOMETHING. WE PULLED TO THE SIDE OF THE ROAD AND TURNED OFF THE IGNITION. WE OPENED THE HOOD AT THAT TIME NOTICED FLAMES COMING FROM UNDER NEATH THE DRIVERS SIDE. WE BARELY HAD ENOUGH TIME TO GET OUT BEFORE IT WAS TOTALLY ENGULFED WITH FLAMES. AT THE TIME WE WERE TOWING AN ENCLOSED TRAILER WITH A 2003 HONDA GOLDWING. NOTHING PRIOR TO THIS INCIDENCE GAVE US ANY CLUE THAT THE VAN WAS ON FIRE. WE LOST ALL OUR POSSESSIONS IN THE VAN AND TRAILER. IT WAS ALL 100% DESTROYED. UNKNOWN CAUSE. WE HAD NOTICED THAT WE WERE USING MORE FUEL. AND WHEN WE PULLED THE VAN OVER TO THE SIDE OF THE ROAD WE NOTICED TRANSMISSION FLUID ON THE GROUND FROM WHERE WE PULLED OVER UNTIL WE GOT STOPPED.

20020826ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

AFTER APPOINTMENT WAS MADE, AND UPON ARRIVAL, DEALERSHIP REFUSED TO DO RECALL OOV110000 REPAIRS.*AK *SLC

20010924EQUIPMENT:MECHANICAL:CARRIER/RACK

THE STEEL CABLE SYSTEM SECURING THE SPARE TIRE RUSTED THROUGHAND SEVERED RELEASING THE SPARE TIRE TO FALL FREELY FROM UNDER THE VAN TO THE ROAD BELOW. AT THE SLOW SPEED I WAS TRAVELING I INCURRED NO LOSS OF CONTROL OR DANGER TO OTHER MOTORISTS, HOWEVER IF I WAS TRAVELING AT HIGHWAY SPEEDS THIS FAILURE WOULD HAVE RESULTED IN A 65MPH MISSLE GOING DOWN THE ROAD. CALLS TO THE MANUFACTURER RESULTED IN NO ACTION. I AM IN POSSESSION OF ALL FAILED PARTS. THANK YOU

20010523STEERING:GEAR BOX (OTHER THAN RACK AND PINION)

WHEN PARKED STEERING WILL NOT TURN. STEERING GEAR BOX & PUMP REPLACED WITH NO EFECT.

20010523STEERING:HYDRAULIC POWER ASSIST:PUMP

WHEN PARKED STEERING WILL NOT TURN. STEERING GEAR BOX & PUMP REPLACED WITH NO EFECT.

20010417ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL

CONSUMER CONTACTED DEALER IN REFERENCE TO RECALL 00V110000/MANUFACTURER'S RECALL 00031 CONCERNING FUEL ODOR/LEAKAGE. DEALER CORRECTED RECALL PROBLEM. CONSUMER BELIEVED RECALL PROBLEM HAS CAUSED ADDITIONAL PROBLEMS IN FUEL SYSTEM. FUEL SYSTEM WAS CONTAMINATED, AND FUEL PUMP/ FILLER NEEDED TO BE REPLACED. PLEASE PROVIDE ANY FURTHER DETAILS.*AK

20010417FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

CONSUMER CONTACTED DEALER IN REFERENCE TO RECALL 00V110000/MANUFACTURER'S RECALL 00031 CONCERNING FUEL ODOR/LEAKAGE. DEALER CORRECTED RECALL PROBLEM. CONSUMER BELIEVED RECALL PROBLEM HAS CAUSED ADDITIONAL PROBLEMS IN FUEL SYSTEM. FUEL SYSTEM WAS CONTAMINATED, AND FUEL PUMP/ FILLER NEEDED TO BE REPLACED. PLEASE PROVIDE ANY FURTHER DETAILS.*AK

20010417FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP

CONSUMER CONTACTED DEALER IN REFERENCE TO RECALL 00V110000/MANUFACTURER'S RECALL 00031 CONCERNING FUEL ODOR/LEAKAGE. DEALER CORRECTED RECALL PROBLEM. CONSUMER BELIEVED RECALL PROBLEM HAS CAUSED ADDITIONAL PROBLEMS IN FUEL SYSTEM. FUEL SYSTEM WAS CONTAMINATED, AND FUEL PUMP/ FILLER NEEDED TO BE REPLACED. PLEASE PROVIDE ANY FURTHER DETAILS.*AK

20010409FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

WHILE DRIVING VEHICLE HAD STALLED OUT. LOST STEERING AND BRAKING POWER. TOWED TO DEALERSHIP. INFORMED BY MECHANIC THAT FUEL PUMP HAD FAILED AND NEEDED TO BE REPLACED. THIS HAS HAPPENED 3 TIMES ALREADY.*AK THE DEALER SAID THERE WAS NO RECALL ON THE FUEL PUMP WHICH WAS FAILING NUMEROUS TIMES. *YH

20010328SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP

DIMINISHED BRAKING ABILITY,DIAGNOSED AS FAULTY ANTI-LOCK SYSTEM. *AK

20001213STEERING:HYDRAULIC POWER ASSIST:PUMP

AFTER MAKING A U TURN, THE POWER STEERING ASSIST WAS LOST. THE POWER STEERING PUMP SHAFT HAD BROKEN MAKING THE VEHICLE NEARLY IMPOSSIBLE TO CONTROL. COULD THIS BE THE PROBLEM OF NHTSA CAMPAIGN #: 96V187000?

20000120CrashAIR BAGS:FRONTAL

WHEN THE VAN WAS INVOLVED IN A PRETTY SEVERE FRONTAL CRASH, PASSENGER'S SIDE AIR BAG DID DEPLOY, BUT THE DRIVER'S SIDE DID NOT. VAN WAS TRAVELING ABOUT 5 MPH WHEN THIS HAPPENED. FRONTAL DAMAGE TOTALLED OVER $7,000 DOLLARS. THE VAN IS BEING REPAIRED. PLEASE PROVIDE ANY FURTHER INFORMATION. *AK

19990329ENGINE AND ENGINE COOLING:ENGINE:DIESEL

ENGINE RUNS RUFF WITH NO POWER. SOUNDS LIKE ENGINE IS DIESELING. BLACK SMOKE COMES OUT OF EXHAUST, SOMTIMES BACKFIRES. ECM NEVER SETS TROUBLE CODE. EVENTUALLY THE ECM SET TROUBLE CODE FOR RIGHT CAT COMMING APART. THE FOURTH (MOST RESENT) BOTH CATS CAME APART. *AK

19990329ELECTRICAL SYSTEM:IGNITION:MODULE

ENGINE RUNS RUFF WITH NO POWER. SOUNDS LIKE ENGINE IS DIESELING. BLACK SMOKE COMES OUT OF EXHAUST, SOMTIMES BACKFIRES. ECM NEVER SETS TROUBLE CODE. EVENTUALLY THE ECM SET TROUBLE CODE FOR RIGHT CAT COMMING APART. THE FOURTH (MOST RESENT) BOTH CATS CAME APART. *AK

19990310VISIBILITY:REARVIEW MIRRORS/DEVICES

NO SUMMARY

19990310EQUIPMENT:APPLIANCE:AIR CONDITIONER

NO SUMMARY

19990113SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP

BRAKE PEDAL MOVES TO 2-3 INCHES BEFORE IT WILL BEGIN TO BRAKE, AND PEDAL TRAVELS TOO FAR DOWN.THIS DEFECT CAUSES INCREASED REACTION TIME. DEALER AND MANUFACTURER CLAIM IT WAS DESIGNED LIKE THAT. *AK

19990113FireELECTRICAL SYSTEM:WIRING:INTERIOR/UNDER DASH

VAN TOTALLY DESTROYED ,HAD BEEN SITTING FOR OVER 2 HOURS BEFORE IT DECIDED TO CATCH FIRE HAD TROUBLE WITH KEYLESS REMOTE PRIOR TO CATCHING FIRE REMOTE WOULD NOT UNLOCK DOORS FIRE STARTED UNDER NEATH PASS. SIDE DASHBOARD IN WHAT I WAS TOLD THE AREA WHERE THE COMPUTER IS

19981103FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY

VEHICLE'S FUEL TANK WAS FILLED ON THE MORINING OF 8/6/98 AND DRIVEN 33 MILES. IT WAS PARKED IN THE DRIVEWAY WITH THE NOSE DOWN ON A 30 DEGREE GRADE. ON THE AFTERNOON OF 8/7/98 AS WE WERE LEAVING ON VACATION I SMELLED GASOLINE WHILE GETTING INTO THE VAN. I LOOKED UNDERNEATH TO FIND FUEL DRAINING FROM OUT UNDERNEATH THE GAS TANK PLASTIC SHIELD ONTO THE DRIVEWAY. IT WAS DETERMINED AT THE DEALERSHIP THAT GAS WAS GOING THROUGH THE VENT PIPE, TO THE CHARCOAL CANISTER AND THEN OUT OF THE CANISTER INTO THE PLASTIC SHIELD AROUND THE TANK. IT WAS ALSO FOUND THAT ONE OF THE TOP SEALS ON THE TANK WAS ALSO LEAKING. MINE WAS THE 3RD EXPRESS VAN AT THE DEALERSHIP WITH A SIMILAR PROBLEM. WITH REPEATED DISCUSSIONS WITH THE FACTORY REP, I WAS TOLD I WOULD HAVE TO PAY FOR THESE SAFETY RELATED DEFECTS AND PARTS OF THE EXACT DESIGN THAT FAILED WERE REINSTALLED. THERE IS AN INHERENT DEFECT IN THIS DESIGN. WHEN THE TANK IS FILLED COOL, AND THE VEHICLE SITS OR IS DRIVEN WITH THE NOSE DOWN AND THE T

Compare 1996CHEVROLETEXPRESS to Similar Vehicles

NHTSA Investigations 2 Open

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Frequently Asked Questions

How many complaints does the 1996 CHEVROLET EXPRESS have?
The 1996 CHEVROLET EXPRESS has 20 NHTSA complaints, 1 crashes, 3 fires, 0 injuries, and 0 deaths reported.
What are the most common problems with the 1996 CHEVROLET EXPRESS?
The most-complained component for the 1996 CHEVROLET EXPRESS is SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP with 2 complaints. Other frequently reported areas include STEERING:HYDRAULIC POWER ASSIST:PUMP and FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP.
Is the 1996 CHEVROLET EXPRESS safe to buy?
Review the complaint history, crash and fire reports, safety ratings, and recall status on this page to make an informed decision. No NHTSA crash test rating is available for this model year. Compare with other model years using the links above.
Where does this data come from?
All complaint, recall, and safety rating data is sourced from the National Highway Traffic Safety Administration (NHTSA). Complaints are filed by vehicle owners through NHTSA's Office of Defects Investigation.

Vehicle Safety Guides

Data as of 2025. Sources: NHTSA Office of Defects Investigation (ODI) complaints database, NHTSA recall campaign API, NHTSA NCAP crash-test ratings, and NHTSA FARS for fatality cross-reference.