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Chevrolet · Known Issues

2025 Chevrolet Express Problems: 2 Known Issues

2025 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated September 2026

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Issue summary

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2025 Chevrolet Express has 2 documented known issues. None of the listed issues is rated critical; this is not a complete reliability assessment. Across all issues with published estimates, repair costs range from $30 to $400. DIY maintenance guides at au7o.io.

In This Article

  • Express Electrical1
  • Express Body/Panels1
  • Recalls7
  • FAQ
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In This Article

  • Electrical1
  • Body/Panels1
  • Recalls7
  • FAQ

All 2 Known Issues

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On the 2008-2025 Chevrolet Express, 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 rings on the hub bearings also corrode.

This issue also affects: Buick Encore GX, Cadillac XTS, Chevrolet Avalanche

Common Symptoms

  • StabiliTrak warning light
  • ABS activating during normal braking
  • Traction control light on
  • Speedometer fluctuating
  • Extended braking distances

How to Fix

Scan for specific wheel speed sensor codes to identify which corner has failed. Replace the faulty wheel speed sensor and inspect the tone ring for corrosion or damage. Clean the sensor mounting area and apply anti-corrosion compound. If the hub bearing is original, replace the entire hub assembly for a fresh tone ring.

Typical repair cost:$150 - $400

Research This Issue

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Community Reported
Medium Confidence

On the 1996-2025 Chevrolet Express, 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.

Common Symptoms

  • Door sags when opened
  • Difficulty closing door
  • Door scrapes on body when opening
  • Wind noise from door area
  • Door latch requires extra force

How to Fix

Replace the door hinge pins and bushings using a hinge repair kit. The door must be supported during the repair. Use a drift punch to remove the old pins and press in new ones. Apply grease to the new pins and bushings. In severe cases where the hinge body is worn, replace the entire hinge.

Typical repair cost:$30 - $200

Research This Issue

GoogleRedditYouTubeNHTSA
Community Reported
Medium Confidence
NHTSA Recalls7 recalls

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.

Campaign #25V08700013/02/2025

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.

Campaign #26V12700005/03/2026

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.

Campaign #25V29900008/05/2025

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.

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Other Chevrolet Models

Chevrolet Silverado 150078Chevrolet Corvette59Chevrolet Equinox58Chevrolet Malibu44Chevrolet Camaro40Chevrolet Traverse37

Frequently Asked Questions

What are the most common Chevrolet Express problems?

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2025 Chevrolet Express has 2 documented issues. The most frequently reported are: StabiliTrak and ABS False Activation from Wheel Speed Sensors, Front Door Hinge Pin and Bushing Wear. None are rated critical, but regular maintenance is recommended.

Is the Chevrolet Express reliable?

The 2025 Chevrolet Express has 2 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. None of the matching records is rated critical; this is not a complete reliability assessment. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Chevrolet Express problems?

Repair costs for known Chevrolet Express issues range from $30 to $400, depending on the specific problem and whether you choose DIY or professional repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 2008-2025 Chevrolet Express StabiliTrak and ABS False Activation from Wheel Speed Sensors?

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.

What is the 1996-2025 Chevrolet Express Front Door Hinge Pin and Bushing Wear?

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.

Data compiled from NHTSA recalls, manufacturer TSBs, automotive forums, and AI-assisted research. No aggregated owner-report counts available for this vehicle yet.

Campaign #26V39900023/06/2026

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.

Campaign #24V83900007/11/2024

+ 2 more recalls. Check all on NHTSA.gov

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