Chevrolet · Known Issues
2015 Chevrolet Express Problems: 12 Known Issues
2015 model year · 510+ owner reports · Updated September 2026
2015 · All trims · All engines
Choose the year and equipment for your written issues and visual request.
2015 model year · 510+ owner reports · Updated September 2026
2015 · All trims · All engines
Choose the year and equipment for your written issues and visual request.
Interest applies to the selected vehicle and configuration; it is not a reservation. Voting stores a first-party identifier for up to 180 days to prevent repeat votes. No account or email is needed. Clearing cookies or using another device may count separately. Privacy
Visual coming soon
Your interest helps us choose what to build next.
Visual Known Issues · Coming soon
$4.99/month plus taxes at launch · No payment today
According to Au7o's analysis of 510+ owner reports, the 2015 Chevrolet Express has 12 documented known issues, with 4 rated critical. The most serious are Fuel Pump Module Failure ($500-$1,000 repair), 6.0L L96 Broken Rocker Arm Causing Misfire and Dropped Valve ($600-$7,500 repair), Cutaway Brake Lines Contacting Body Mounts and Leaking (Recall 24V702) ($0-$0 repair) and Driver Power Window Switch Corrosion and Underlying Fire Risk (Recall 18V295) ($0-$0 repair). The most commonly reported issue is Fuel Pump Module Failure with 290 owner reports. Across all issues with published estimates, repair costs range from $30 to $7,500. DIY maintenance guides at au7o.io.
STRUCTURE:BODY:DOOR
General Motors LLC (GM) is recalling certain 2025 Chevrolet Express and GMC Savana vans. The impact beam located in the driver's side door may have improper welds.
TIRES:SIDEWALL
General Motors, LLC (GM) is recalling certain 2025-2026 Express Cutaway, and 2025-2026 Savana Cutaway vehicles. These vehicles may be equipped with a tire with sidewall damage.
SEATS:FRONT ASSEMBLY:HEAD RESTRAINT
General Motors LLC (GM) is recalling certain 2025 Chevrolet Express and GMC Savana vehicles. The front passenger seat head restraint may have been improperly welded to the seat frame.
STEERING
General Motors, LLC (GM) is recalling certain 2025-2026 Express, and 2025-2026 Savana vehicles. The steering gear assembly may have a nut that was not properly tightened.
POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE:SOFTWARE
General Motors, LLC (GM) is recalling certain 2022-2023 Chevrolet Express and GMC Savana vehicles. Incorrect software in the transmission control module (TCM) may result in harsh shifting, reduced power, unintended deceleration, rear wheel lockup, or cause the vehicle to move in an unintended direction.
+ 2 more recalls. Check all on NHTSA.gov
Enter your VIN at NHTSA.gov to check recalls specific to your vehicle.
Don't see your problem? Describe your symptoms to get a diagnosis, or get a full repair guide.
According to Au7o's analysis of 510+ owner reports, the 2015 Chevrolet Express has 12 documented issues. The most frequently reported are: Fuel Pump Module Failure, 6.0L L96 Broken Rocker Arm Causing Misfire and Dropped Valve, Cutaway Brake Lines Contacting Body Mounts and Leaking (Recall 24V702). Of these, 4 are rated critical and should be addressed promptly.
The 2015 Chevrolet Express has 12 known issues documented across 510+ owner reports. 4 issues are rated critical: Fuel Pump Module Failure and 6.0L L96 Broken Rocker Arm Causing Misfire and Dropped Valve and Cutaway Brake Lines Contacting Body Mounts and Leaking (Recall 24V702) and Driver Power Window Switch Corrosion and Underlying Fire Risk (Recall 18V295). Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
Repair costs for known Chevrolet Express issues range from $0 to $7,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Fuel Pump Module Failure, typically costs $500-$1,000 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
In-tank fuel pump fails causing stalling, hard starts, and no-start conditions. Often fails without warning on high-mileage vans. Repairs typically run $500-$1,000. Severity: high.
Vans built with the 6.0L L96/LC8 Vortec V8 (the volume engine in Express 2500/3500 from 2010 on) can break a rocker arm, producing an engine tick and a hard misfire on one cylinder. GM addressed it in preliminary information bulletin PIP5522B, which specifically lists 2017-2018 C… Repairs typically run $600-$7,500. Severity: high.
This one is specific to the cutaway body, which is exactly the fitment trap on this nameplate. GM recalled 2013-2019 Chevrolet Express Cutaway and GMC Savana Cutaway vehicles built with the optional GM-provided body mounts (RPO BNC) because the brake lines were not routed with th… Repairs typically run $0-$0. Severity: high.
GM recalled more than 207,000 2014-2017 Chevrolet Express and GMC Savana vans because liquid can leak into the driver's door power window switch and corrode the circuit board. The corrosion creates high electrical resistance at the switch contacts, which generates heat and can st… Repairs typically run $0-$0. Severity: high.
Sliding door hinge pins and rollers wear causing the door to sag, stick, or not latch properly. Very common on work vans with frequent use. Repairs typically run $150-$400. Severity: medium.
The wheel speed sensors and their wiring are prone to failure due to the harsh commercial-use environment, causing the StabiliTrak and ABS systems to falsely activate during normal driving. The ABS unexpectedly engages during normal braking, extending stopping distances. The tone… Repairs typically run $150-$400. Severity: medium.
The cast-iron exhaust manifolds on the Vortec small-block V8s bolt to aluminum cylinder heads. The two materials expand at very different rates, and after thousands of heat cycles the manifold repeatedly loads the outer bolts until they snap - almost always the front-most and rea… Repairs typically run $400-$1,600. Severity: medium.
The 6.6L Duramax LGH offered in Express 2500/3500/4500 vans from 2011 to 2016 has a well-documented glow plug system weakness. Individual glow plugs fail open, and the glow plug control module itself develops open-driver and no-power-to-glow-plug faults - a failure mode common en… Repairs typically run $300-$1,800. Severity: medium.
When the Express moved to the 6L80 and 6L90 six-speed for the 2010 and later vans, it inherited that family's torque converter clutch problem. The TCC lining delaminates, and the shed material scores the fluid pump - so what starts as a light shudder felt at steady cruise, often… Repairs typically run $300-$3,500. Severity: medium.
Express vans ordered with rear air conditioning - which is most passenger and shuttle configurations - run refrigerant and coolant lines the full length of the body to a rear evaporator and heater core mounted behind the interior trim. That long run is the system's weak point. Le… Repairs typically run $300-$1,500. Severity: medium.
The Express uses a sealed front hub/bearing assembly with the ABS wheel speed sensor built into the top of the unit. Two things go wrong. First, on a heavily loaded van the bearing itself wears out and produces a roar or growl that rises with road speed and changes when you sway… Repairs typically run $250-$900. Severity: medium.
The front door hinge pins and bushings wear out from the heavy doors and frequent commercial use, causing the doors to sag. Sagging doors do not latch properly, create wind noise, and are difficult to close. The driver door is typically the first to sag due to heavier usage. Repairs typically run $30-$200. Severity: low.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.