2009 Chevrolet EXPRESS 3500 problems and owner complaints
Explore the records behind recurring owner reports.
Key facts
9 owner complaints analyzed
2 distinct recall campaigns
59,747 mi median reported failure mileage
Scope: 2009 model year. Data updated: . 9 complaints include usable failure mileage. View data status.
This selection has limited data. It remains available for lookup but is excluded from search indexing.
Most common problems
Air Bags:Side/Window:Curtain is the most frequently named component, appearing in 1 of 9 complaints (11.1%). A complaint can name multiple components.
Component breakdown
Number of unique complaints naming each component. Top eight shown.
| Category | Count |
|---|---|
| Air Bags:Side/Window:Curtain | 1 |
| Electrical System | 1 |
| Electrical System:Ignition | 1 |
| Fuel System, Diesel | 1 |
| Fuel System, Gasoline | 1 |
| Fuel System, Gasoline:Storage:Tank Assembly:Filler Pipe And Cap | 1 |
| Structure:Body | 1 |
| Tires | 1 |
Air Bags:Side/Window:Curtain: 1; Electrical System: 1; Electrical System:Ignition: 1; Fuel System, Diesel: 1; Fuel System, Gasoline: 1; Fuel System, Gasoline:Storage:Tank Assembly:Filler Pipe And Cap: 1; Structure:Body: 1; Tires: 1
Reported problems by failure mileage
Complaint counts in mileage bands. These are not failure rates per vehicle or mile.
| Category | Count |
|---|---|
| Under 25,000 | 2 |
| 25,000 to 49,999 | 0 |
| 50,000 to 74,999 | 3 |
| 75,000 to 99,999 | 2 |
| 100,000 to 149,999 | 2 |
| 150,000 and above | 0 |
Under 25,000: 2; 25,000 to 49,999: 0; 50,000 to 74,999: 3; 75,000 to 99,999: 2; 100,000 to 149,999: 2; 150,000 and above: 0
50,000 to 74,999 miles has the most reports with usable mileage (3). 0 complaints have missing, zero or invalid mileage.
Complaints over time
Year the complaint was filed, not the vehicle model year or incident year. The snapshot year is partial.
| Category | Count |
|---|---|
| 2010 | 2 |
| 2011 | 1 |
| 2014 | 2 |
| 2015 | 3 |
| 2017 | 1 |
2010: 2; 2011: 1; 2014: 2; 2015: 3; 2017: 1
Pattern summary
Air Bags:Side/Window:Curtain leads the component reports. Use these patterns to inspect individual reports and prepare questions for a mechanic.
Calculated from recorded counts. An AI narrative has not been published for this selection.
Complaint evidence
Examples provide context, not a representative sample or a verified diagnosis.
Vehicle analysis explorer
Inspect model-year patterns, reported mileage, monthly activity and the evidence behind each signal.
Data completeness
9 unique complaints in this selection. Analysis snapshot: 2026-10-01.
Missing, zero and invalid mileage is excluded. Dates after the snapshot are excluded. Examples are limited selections, not a representative sample.
Problems by model year
Model-wide comparison of the eight most reported components across the model. Cells show counts and shares within each model year. Open a cell for source examples.
| Component | 2010 | 2012 | 2013 | 2014 | 2019 | 2021 | 2024 |
|---|---|---|---|---|---|---|---|
| Electrical System | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 1100.0%ODI 11724714 · 20,300 miThe contact owns a 2021 Chevrolet Express 3500. The contact stated that while driving 30 MPH, there was a burning odor coming from the vehicle, and the vehicle was pulled over into the right lane. Upon exiting the vehicle, the contact became aware that the front wheels were smoking. Additionally, the brake pedal went to the floorboard while depressed. The contact stated that the brake fluid seemed to be boiling. The contact was on a trip, and the vehicle was driven to a campground. The vehicle was later driven to a dealer. The contact reference… | 00.0%No examples available for this selection. |
| Fuel/Propulsion System | 00.0%No examples available for this selection. | 360.0%ODI 11064792 · 150,000 miHAVE 2 2012 CHEVY CUT AWAY VAN SCHOOL BUSES WITH THE FUEL PUMP MODULE START LEAKING. 1 LEAKED ON THE PRESSURE LINE,THE OTHER ON THE VENT LINE. BOTH BUSES HAVE LESS THAN 150000 MILES. | 00.0%No examples available for this selection. | 1100.0%ODI 10970168 · 22,000 miON DELIVERY GASOLINE LEAKED FROM FILLER TUBE.DEALER FINALLY REPAIRED FILLER TUBE AFTER SEVERAL ATTEMPTS. LEAK HAS RECURRED AND GASOLINE LEAKS ONTO VEHICLE AND GROUND DURING REFUELING. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. |
| Service Brakes, Hydraulic | 125.0%ODI 10410077 · 30,000 miTL* THE CONTACT OWNS A 2010 CHEVROLET EXPRESS CUTAWAY G3500. THE CONTACT NOTICED THAT THE FRONT END WAS SHAKING EXCESSIVELY WHILE APPLYING PRESSURE TO THE BRAKES, CAUSING HIM TO LOSE CONTROL OF THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THEY REPLACED THE FRONT BRAKE ROTORS;HOWEVER, THE VEHICLE CONTINUED TO SHAKE EXCESSIVELY AT ANY SPEED WHEN THE BRAKE PEDAL WAS ENGAGED. THE MANUFACTURER WAS AWARE OF THE FAILURE. THE CURRENT MILEAGE WAS 53,300. THE APPROXIMATE FAILURE MILEAGE WAS 30,000. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. |
| Steering | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 150.0%ODI 11697388Fluid leaking from hydraulic power brake booster causing longer braking distance & stiffer steering. | 00.0%No examples available for this selection. | 150.0%ODI 11640062The vehicle shakes at speeds starting at 68 mph and is extreme at 73 mph. I have taken it in for repairs at the Chevrolet dealership twice and to a tire shop. I fear this could be the start of the term known as the "Death Wobble". Chevrolet is aware of this issue and have issued Technical Service Bulletins relating to shake and vibration complaints. This is a brand new 2025 vehicle. Because this vibration/shake occurs it highway speeds a mechanical failure could cause serious injury or death. I have contacted the manufacturer and they do not wi… |
| Service Brakes | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 2100.0%ODI 11639642Unable to get a recall remedy vehicle has been undrivable since November . With no ETA on when part will be available. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. |
| Tires | 125.0%ODI 10489377AUGUST 2011 OUR AMBULANCE DEPARTMENT PURCHASED 6 NEW TIRES FOR OUR CHEVY AMBULANCE. JANUARY 2012 WE HAD A BELT SEPARATION ON A FRONT DRIVER TIRE. APRIL 2012 WE HAD ANOTHER TIRE HAVE A BELT SEPARATION ON THE PASSENGER TIRE. THEN DECEMBER 2012 WE HAD A BACK INSIDE DUAL TIRE HAVE BELT SEPARATION. I HAVE NOW REPLACED ALL THE TIRES WITH A PRODUCTION DATE OF 2311. THESE TIRES ARE THE LT22575R16. *TR | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. |
| Fuel System, Gasoline | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. |
| Engine | 125.0%ODI 10704835 · 19,700 miSOMETIMES WHEN ATTEMPTING TO START THE ENGINE, IT WILL TURN OVER BUT NOT START. THE MALFUNCTION INDICATOR LIGHT COMES ON AND A ENGINE REDUCED POWER MESSAGE WILL ILLUMINATE. IF THE ENGINE STARTS, IT WILL RUN ROUGH, THE LIGHT WILL BE ON AND STAY ON, AND THE ENGINE REDUCED POWER MESSAGE WILL APPEAR. I HAD A MECHANIC CHECK FOR ANY CODES AND HE CAME UP WITH P1682, WHICH INDICATES AN IGNITION SWITCH PROBLEM. GM HAS A RECALL OUT FOR THIS CONDITION (11273), WHICH REFERS TO THE THROTTLE POSITION SENSOR CAUSING THIS PROBLEM. HOWEVER A FAULTY IGNITION SWI… | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. |
Darker cells indicate a larger share of submitted complaints. Components overlap. This measures complaint composition, not failure probability.
Failure mileage by component
Median and middle 50% of usable owner-reported mileages. Ranges require at least five records.
| Component | Mileage range (25th–75th percentile) | Median | Usable records | Examples |
|---|---|---|---|---|
| Air Bags:Side/Window:Curtain | Too few reports for a range | 59,747 mi | 1 (sparse) | ODI 10760744 · 59,747 miTL* THE CONTACT OWNS A 2009 CHEVROLET EXPRESS 3500. UPON STARTING THE VEHICLE, THE SERVICE AIR BAG INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE ROLL OVER SENSOR BECAME INOPERABLE AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 59,747. |
| Electrical System | Too few reports for a range | 110,000 mi | 1 (sparse) | ODI 10588522 · 110,000 miTL* THE CONTACT OWNS A 2009 CHEVROLET EXPRESS 3500. THE CONTACT STATED THAT THE KEY FAILED TO TURN IN THE IGNITION IN ORDER TO START THE VEHICLE AND THE KEY COULD BE REMOVED FROM THE IGNITION WHILE THE VEHICLE WAS TURNED ON. THIS FAILURE OCCURRED INTERMITTENTLY FOR SEVERAL YEARS. THE VEHICLE WAS TAKEN TO A DEALER WHO STATED A NEW KEY WAS NEEDED TO REPAIR THE FAILURE. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE DEFECT. THE APPROXIMATE FAILURE MILEAGE WAS 110,000. |
| Electrical System:Ignition | Too few reports for a range | 110,000 mi | 1 (sparse) | ODI 10588522 · 110,000 miTL* THE CONTACT OWNS A 2009 CHEVROLET EXPRESS 3500. THE CONTACT STATED THAT THE KEY FAILED TO TURN IN THE IGNITION IN ORDER TO START THE VEHICLE AND THE KEY COULD BE REMOVED FROM THE IGNITION WHILE THE VEHICLE WAS TURNED ON. THIS FAILURE OCCURRED INTERMITTENTLY FOR SEVERAL YEARS. THE VEHICLE WAS TAKEN TO A DEALER WHO STATED A NEW KEY WAS NEEDED TO REPAIR THE FAILURE. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE DEFECT. THE APPROXIMATE FAILURE MILEAGE WAS 110,000. |
| Fuel System, Diesel | Too few reports for a range | 82,000 mi | 1 (sparse) | ODI 10373566 · 82,000 miCHEVY EXPRESS 4500 DIESEL CUTAWAY. FUEL OIL HEATER (FOH) IS AN AUXILIARY HEATER LOCATED UNDER THE CAB OF THE VEHICLE AND EXHAUSTS IN THE SAME AREA. ODOR OF PARTIALLY BURNED FUEL AND A STRONG EXHAUST SMALL WOULD ENTER THE CAB OF THE VEHICLE DURING LOW SPEED OPERATION IN COLD WEATHER. DUE TO THE INTERMITTENT CHARACTER OF THE ODOR A HOME CO MONITOR WAS PLACED IN THE CAB OF THE VEHICLE WHICH DID ALARM, PROMPTING THE VEHICLE TO BE REMOVED FROM SERVICE AND SENT FOR REPAIR. THE FOH REQUIRED REPLACEMENT. *TR |
| Fuel System, Gasoline | Too few reports for a range | 18,000 mi | 1 (sparse) | ODI 10416916 · 18,000 miWHEN REFUELING THIS VEHICLE, THE GASOLINE DOES NOT FLOW WITH EASE THROUGH THE INTAKE TUBES. IT BACKS UP, OVERFLOWING THE FILLER PIPE, SPILLING OUT OR SHUTTING OFF THE GAS NOZZLE REPEATEDLY. IT CAN TAKE TEN MINUTES TO PUT TEN GALLONS OF GASOLINE IN THE TANK. THERE ARE MANY OTHER OWNERS HAVING THE SAME PROBLEM. IT HAS HAPPENED ALMOST EVERY TIME WE PUT GASOLINE IN THE TANK. NOT JUST ONE INCIDENT FOR SURE. THIS IS ON THE CHEVY EXPRESS 3500 WHICH HAS BEEN MADE INTO A 2009 ROADTREK MOTORHOME VERSATILE 210. *KB |
| Fuel System, Gasoline:Storage:Tank Assembly:Filler Pipe And Cap | Too few reports for a range | 18,000 mi | 1 (sparse) | ODI 10416916 · 18,000 miWHEN REFUELING THIS VEHICLE, THE GASOLINE DOES NOT FLOW WITH EASE THROUGH THE INTAKE TUBES. IT BACKS UP, OVERFLOWING THE FILLER PIPE, SPILLING OUT OR SHUTTING OFF THE GAS NOZZLE REPEATEDLY. IT CAN TAKE TEN MINUTES TO PUT TEN GALLONS OF GASOLINE IN THE TANK. THERE ARE MANY OTHER OWNERS HAVING THE SAME PROBLEM. IT HAS HAPPENED ALMOST EVERY TIME WE PUT GASOLINE IN THE TANK. NOT JUST ONE INCIDENT FOR SURE. THIS IS ON THE CHEVY EXPRESS 3500 WHICH HAS BEEN MADE INTO A 2009 ROADTREK MOTORHOME VERSATILE 210. *KB |
| Structure:Body | Too few reports for a range | 92,000 mi | 1 (sparse) | ODI 10954471 · 92,000 miEXTERIOR PAINT PEELS & FLAKES OFF IN SHEETS AS OF NOT ADHERING TO THE METAL. PEELS OFF BOTH WHILE DRIVING & WHEN PARKED. FLAKING OF PAINT IS CONTINUOUS. |
| Tires | Too few reports for a range | 14,000 mi | 1 (sparse) | ODI 10605027 · 14,000 miVEHICLE WAS SHAKING. TOOK TO [XXX] INC.IN SYRACUSE, NY FOR ALIGNMENT. WAS TOLD VEHICLE WAS IN ALIGNMENT. WAS TOLD THAT THE STEEL BELTS IN THE TIRES WERE BAD DUE TO TIRES BULGING ON THE OUTSIDE AND INDENTED IN THE CENTER OF THE TIRE. WOULD NOT RECOMMEND TIRE ROTATION. ALL 6 TIRES ARE EFFECTED. THE WORSE TIRE PASSENGER FRONT WAS USED IN THE DATA COLLECTED BY THIS SITE. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR |
Complaint and recall timeline
Explore monthly filing activity alongside recall announcements. Up to ten years of monthly history is available.
Solid line: filed complaints. Dashed amber lines: recall announcement dates for this vehicle selection; markers include all recall components. The latest month is partial. Temporal proximity does not establish causation.
Monthly counts, recall campaigns and complaint examples
| Month | Complaints | Campaigns announced | Examples |
|---|---|---|---|
| 2024-11 | 0 | None | No examples available for this selection. |
| 2024-12 | 0 | None | No examples available for this selection. |
| 2025-01 | 0 | None | No examples available for this selection. |
| 2025-02 | 0 | None | No examples available for this selection. |
| 2025-03 | 0 | None | No examples available for this selection. |
| 2025-04 | 0 | None | No examples available for this selection. |
| 2025-05 | 0 | None | No examples available for this selection. |
| 2025-06 | 0 | None | No examples available for this selection. |
| 2025-07 | 0 | None | No examples available for this selection. |
| 2025-08 | 0 | None | No examples available for this selection. |
| 2025-09 | 0 | None | No examples available for this selection. |
| 2025-10 | 0 | None | No examples available for this selection. |
| 2025-11 | 0 | None | No examples available for this selection. |
| 2025-12 | 0 | None | No examples available for this selection. |
| 2026-01 | 0 | None | No examples available for this selection. |
| 2026-02 | 0 | None | No examples available for this selection. |
| 2026-03 | 0 | None | No examples available for this selection. |
| 2026-04 | 0 | None | No examples available for this selection. |
| 2026-05 | 0 | None | No examples available for this selection. |
| 2026-06 | 0 | None | No examples available for this selection. |
| 2026-07 | 0 | None | No examples available for this selection. |
| 2026-08 | 0 | None | No examples available for this selection. |
| 2026-09 | 0 | None | No examples available for this selection. |
| 2026-10 (partial) | 0 | None | No examples available for this selection. |
Emerging complaint spikes
Complete months in the latest six months with at least 10 complaints, at least twice the preceding 12-month average, and at least three square-root deviations above that average.
This is a descriptive screening rule, not a statistical defect finding. Publicity and reporting changes can increase submissions.
No complete months meet the spike thresholds for this selection.
Equal-age model-year comparison
Model-wide cumulative reports during the first three or five calendar years, starting with the model year (age 0). Only fully elapsed windows are compared.
2019: 0 complaints · 2021: 0 complaints
| Model year | Through age 0 | Through age 1 | Through age 2 |
|---|---|---|---|
| 2019 | 0 | 0 | 0 |
| 2021 | 0 | 0 | 0 |
Date coverage across each selected cohort
| Year | Incident dates used | Filing date fallbacks | Excluded dates |
|---|---|---|---|
| 2019 | 2 | 0 | 0 |
| 2021 | 1 | 0 | 0 |
Incident date is preferred when valid and no later than filing; otherwise filing date is used. Model year approximates age. Equal observation time does not adjust for sales, distance driven or reporting delays. One complaint linked to multiple model years can appear in each cohort.
Components reported together
Each cell counts unique complaints naming both components. Open a nonzero cell for examples.
| Component | Air Bags:Side/Window:Curtain | Electrical System | Electrical System:Ignition | Fuel System, Diesel | Fuel System, Gasoline | Fuel System, Gasoline:Storage:Tank Assembly:Filler Pipe And Cap | Structure:Body | Tires |
|---|---|---|---|---|---|---|---|---|
| Air Bags:Side/Window:Curtain | — | 0 | 0 | 0 | 0 | 0 | 0 | 0 |
| Electrical System | 0 | — | 1ODI 10588522 · 110,000 miTL* THE CONTACT OWNS A 2009 CHEVROLET EXPRESS 3500. THE CONTACT STATED THAT THE KEY FAILED TO TURN IN THE IGNITION IN ORDER TO START THE VEHICLE AND THE KEY COULD BE REMOVED FROM THE IGNITION WHILE THE VEHICLE WAS TURNED ON. THIS FAILURE OCCURRED INTERMITTENTLY FOR SEVERAL YEARS. THE VEHICLE WAS TAKEN TO A DEALER WHO STATED A NEW KEY WAS NEEDED TO REPAIR THE FAILURE. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE DEFECT. THE APPROXIMATE FAILURE MILEAGE WAS 110,000. | 0 | 0 | 0 | 0 | 0 |
| Electrical System:Ignition | 0 | 1ODI 10588522 · 110,000 miTL* THE CONTACT OWNS A 2009 CHEVROLET EXPRESS 3500. THE CONTACT STATED THAT THE KEY FAILED TO TURN IN THE IGNITION IN ORDER TO START THE VEHICLE AND THE KEY COULD BE REMOVED FROM THE IGNITION WHILE THE VEHICLE WAS TURNED ON. THIS FAILURE OCCURRED INTERMITTENTLY FOR SEVERAL YEARS. THE VEHICLE WAS TAKEN TO A DEALER WHO STATED A NEW KEY WAS NEEDED TO REPAIR THE FAILURE. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE DEFECT. THE APPROXIMATE FAILURE MILEAGE WAS 110,000. | — | 0 | 0 | 0 | 0 | 0 |
| Fuel System, Diesel | 0 | 0 | 0 | — | 0 | 0 | 0 | 0 |
| Fuel System, Gasoline | 0 | 0 | 0 | 0 | — | 1ODI 10416916 · 18,000 miWHEN REFUELING THIS VEHICLE, THE GASOLINE DOES NOT FLOW WITH EASE THROUGH THE INTAKE TUBES. IT BACKS UP, OVERFLOWING THE FILLER PIPE, SPILLING OUT OR SHUTTING OFF THE GAS NOZZLE REPEATEDLY. IT CAN TAKE TEN MINUTES TO PUT TEN GALLONS OF GASOLINE IN THE TANK. THERE ARE MANY OTHER OWNERS HAVING THE SAME PROBLEM. IT HAS HAPPENED ALMOST EVERY TIME WE PUT GASOLINE IN THE TANK. NOT JUST ONE INCIDENT FOR SURE. THIS IS ON THE CHEVY EXPRESS 3500 WHICH HAS BEEN MADE INTO A 2009 ROADTREK MOTORHOME VERSATILE 210. *KB | 0 | 0 |
| Fuel System, Gasoline:Storage:Tank Assembly:Filler Pipe And Cap | 0 | 0 | 0 | 0 | 1ODI 10416916 · 18,000 miWHEN REFUELING THIS VEHICLE, THE GASOLINE DOES NOT FLOW WITH EASE THROUGH THE INTAKE TUBES. IT BACKS UP, OVERFLOWING THE FILLER PIPE, SPILLING OUT OR SHUTTING OFF THE GAS NOZZLE REPEATEDLY. IT CAN TAKE TEN MINUTES TO PUT TEN GALLONS OF GASOLINE IN THE TANK. THERE ARE MANY OTHER OWNERS HAVING THE SAME PROBLEM. IT HAS HAPPENED ALMOST EVERY TIME WE PUT GASOLINE IN THE TANK. NOT JUST ONE INCIDENT FOR SURE. THIS IS ON THE CHEVY EXPRESS 3500 WHICH HAS BEEN MADE INTO A 2009 ROADTREK MOTORHOME VERSATILE 210. *KB | — | 0 | 0 |
| Structure:Body | 0 | 0 | 0 | 0 | 0 | 0 | — | 0 |
| Tires | 0 | 0 | 0 | 0 | 0 | 0 | 0 | — |
Co-reporting does not establish that one component caused another concern.
Recurring narrative patterns
Specific keyword mentions beyond broad component labels. Matching includes negations and comparisons and does not confirm a diagnosis.
0 patterns with matching reports.
No narratives match the published patterns.