2009 Chevrolet Express Cargo

The 2009 Chevrolet Express Cargo van is a full-size workhorse known for its reliability, spacious cargo area, and robust truck-based platform. Engine options for the 2009 model year include the 4.3L V6 (195 hp, 260 lb-ft torque), the 5.3L V8 (310 hp, 338 lb-ft torque), and the 6.0L V8 (300 hp, 360 lb-ft torque or 322 hp, 373 lb-ft torque depending on configuration). Transmission options consist of a 4-speed automatic transmission and a 6-speed automatic transmission, depending on the engine. Owners often praise the van’s durability and cargo capacity, but common complaints include fuel economy and some recurring mechanical issues.

Engine

4.3L V6

• Intake Manifold Gasket Leak
  • Description/Symptoms: Coolant leak, overheating, rough running engine.
  • Solution: Replace the intake manifold gasket.
  • Estimated Cost to Fix: $300 - $600+
  • Recalls: None Found

5.3L V8

• Active Fuel Management (AFM) Lifter Failure
  • Description/Symptoms: Misfires, ticking noise from the engine, poor performance. This is more common on engines that have not had regular oil changes.
  • Solution: Replace the failed lifters and possibly the camshaft. AFM delete kits are also available as a more permanent solution.
  • Estimated Cost to Fix: $1500 - $3000+
  • Recalls: None Found
• Oil Consumption
  • Description/Symptoms: Excessive oil consumption, blue smoke from the exhaust, low oil level.
  • Solution: Replace the valve seals, piston rings, or potentially the entire engine depending on the severity.
  • Estimated Cost to Fix: $500 - $5000+ depending on the solution
  • Recalls: None Found

6.0L V8

• No Issues Found

Transmission

4-Speed Automatic Transmission (4L60E)

• Transmission Slipping/Rough Shifting
  • Description/Symptoms: Delayed engagement, harsh shifts, slipping between gears, especially between 2nd and 3rd gear.
  • Solution: Rebuild or replace the transmission. Valve body issues are common in these transmissions.
  • Estimated Cost to Fix: $1500 - $3500+
  • Recalls: None Found

6-Speed Automatic Transmission (6L80E)

• Torque Converter Failure
  • Description/Symptoms: Shuddering at low speeds, especially under light acceleration. Can also cause a P0741 trouble code.
  • Solution: Replace the torque converter. Flushing the transmission is a good idea to remove any debris.
  • Estimated Cost to Fix: $800 - $1500+
  • Recalls: None Found

Suspension

• Leaf Spring Sagging/Broken
  • Description/Symptoms: Rear of the vehicle sagging, rough ride, clunking noises from the rear suspension.
  • Solution: Replace the leaf springs.
  • Estimated Cost to Fix: $500 - $1000+
  • Recalls: None Found
• Worn Ball Joints and Tie Rod Ends
  • Description/Symptoms: Loose steering, wandering, clunking noises from the front suspension, uneven tire wear.
  • Solution: Replace the worn ball joints and tie rod ends.
  • Estimated Cost to Fix: $300 - $800+ per side.
  • Recalls: None Found

Electrical

• Door Lock Actuator Failure
  • Description/Symptoms: Door locks not working properly, intermittent locking/unlocking, clicking noise from the door.
  • Solution: Replace the faulty door lock actuator.
  • Estimated Cost to Fix: $150 - $300+ per door.
  • Recalls: None Found
• Blower Motor Resistor Failure
  • Description/Symptoms: Blower motor only working on certain speeds, or not working at all.
  • Solution: Replace the blower motor resistor.
  • Estimated Cost to Fix: $50 - $200+
  • Recalls: None Found

Exterior

• Rust on Lower Body Panels
  • Description/Symptoms: Rust forming on the rocker panels, wheel wells, and lower doors.
  • Solution: Rust repair and body work.
  • Estimated Cost to Fix: $500 - $3000+ depending on the severity.
  • Recalls: None Found

Interior

• Seatbelt Retractor Failure
  • Description/Symptoms: Seatbelt not retracting properly or at all.
  • Solution: Replace the seatbelt assembly.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found

Summary

The 2009 Chevrolet Express Cargo, while generally a reliable vehicle, does exhibit some common issues. Engine problems, particularly AFM lifter failure on the 5.3L V8, and transmission issues (slipping in the 4L60E and torque converter problems in the 6L80E) can lead to significant repair costs. Suspension wear is also common, especially with the leaf springs. Electrical problems like door lock actuator failure are generally less costly to fix. Rust is a concern, especially in regions with road salt. Overall, potential buyers should inspect the vehicle carefully for these issues and budget accordingly.