2016 Chevrolet Express 3500

Here is a comprehensive list of common issues and complaints for the 2016 Chevrolet Express 3500, formatted as requested. The 2016 Chevrolet Express 3500 is a full-size van known for its utility and robustness. Engine options for this model year include a 4.8L V8 (285 hp, 295 lb-ft torque), a 6.0L V8 (342 hp, 373 lb-ft torque), and a 6.6L Duramax Diesel V8 (260 hp, 525 lb-ft torque). The standard transmission is a 6-speed automatic. Owners often appreciate the vehicle’s spacious cargo area and towing capacity, but frequently cite concerns about fuel economy and dated interior design.

Engine

4.8L V8

• Oil Consumption
  • Description/Symptoms: Excessive oil consumption between oil changes, often noticeable via the oil level dropping significantly before the next scheduled change.
  • Solution: Monitor oil levels frequently. Consider switching to a heavier weight oil. In severe cases, engine rebuild or replacement may be necessary.
  • Estimated Cost to Fix: $100 (oil change) - $5,000+ (engine replacement)
  • Recalls: None Found

6.0L V8

• Active Fuel Management (AFM) Lifter Failure
  • Description/Symptoms: Ticking or knocking sound from the engine, rough idling, misfires, and reduced power, often triggered by lifter collapse due to AFM system malfunction.
  • Solution: Replace faulty lifters. Consider disabling the AFM system with a tuner or AFM delete kit to prevent future issues.
  • Estimated Cost to Fix: $2,000 - $4,000+
  • Recalls: None Found

6.6L Duramax Diesel V8

• Diesel Exhaust Fluid (DEF) System Issues
  • Description/Symptoms: “Service Exhaust Fluid System” message, reduced engine power, potential for the engine to go into limp mode. Issues can stem from faulty DEF level sensors, DEF quality sensors, or DEF injector clogging.
  • Solution: Diagnose the specific component causing the issue. Replace the faulty sensor, DEF injector, or perform a DEF system flush.
  • Estimated Cost to Fix: $200 - $1,500+
  • Recalls: None Found
• Fuel Injector Failure
  • Description/Symptoms: Rough running engine, poor fuel economy, excessive exhaust smoke (black or white), and potential for engine misfires.
  • Solution: Replace the faulty fuel injector(s). Ensure proper fuel filtration to prevent future issues.
  • Estimated Cost to Fix: $500 - $2,000+
  • Recalls: None Found

Transmission

6-Speed Automatic (All Engines)

• Torque Converter Shudder
  • Description/Symptoms: A noticeable shudder or vibration felt during light acceleration, particularly at lower speeds. Often linked to contaminated or degraded transmission fluid.
  • Solution: Perform a complete transmission fluid flush, ensuring the correct type of fluid is used. If the shudder persists, the torque converter may need to be replaced.
  • Estimated Cost to Fix: $300 - $1,500+
  • Recalls: None Found
• Harsh Shifting
  • Description/Symptoms: Rough or abrupt gear changes, especially between 1st and 2nd gear.
  • Solution: Check and adjust transmission fluid level. Consider a transmission flush and filter change. In some cases, the valve body may need to be rebuilt or replaced.
  • Estimated Cost to Fix: $200 - $2,500+
  • Recalls: None Found

Suspension

• Leaf Spring Sagging/Cracking
  • Description/Symptoms: Rear of the vehicle sitting lower than normal, reduced ride quality, and potential for cracking or breaking of the leaf springs, especially when heavily loaded.
  • Solution: Replace the leaf springs. Consider upgrading to heavy-duty leaf springs if the vehicle is frequently used for hauling heavy loads.
  • Estimated Cost to Fix: $500 - $1,500+
  • Recalls: None Found

Electrical

• Battery Drain
  • Description/Symptoms: Battery draining overnight or over a few days, difficulty starting the vehicle, and potential for the battery to become completely discharged. Often caused by parasitic draw from a faulty module or accessory.
  • Solution: Perform a parasitic draw test to identify the source of the drain. Repair or replace the faulty component.
  • Estimated Cost to Fix: $100 - $500+
  • Recalls: None Found
• Door Lock Actuator Failure
  • Description/Symptoms: Door locks failing to operate correctly, difficulty locking or unlocking doors, and potential for the locks to become stuck in either the locked or unlocked position.
  • Solution: Replace the faulty door lock actuator.
  • Estimated Cost to Fix: $150 - $400+ per door
  • Recalls: None Found

Exterior

• Side Door Cable Failure
  • Description/Symptoms: Side doors failing to open or close smoothly, difficulty operating the side doors, and potential for the cable to snap.
  • Solution: Replace the faulty side door cable.
  • Estimated Cost to Fix: $200 - $500+ per door
  • Recalls: None Found

Interior

• HVAC Blower Motor Failure
  • Description/Symptoms: No air blowing from the vents, weak airflow, or unusual noises coming from the blower motor area.
  • Solution: Replace the faulty blower motor.
  • Estimated Cost to Fix: $150 - $400+
  • Recalls: None Found

Summary

The 2016 Chevrolet Express 3500 presents a mix of common issues. Engine problems, particularly with the AFM system in the 6.0L V8 and DEF issues in the diesel, can be costly. Transmission issues can range from relatively inexpensive fluid flushes to significant torque converter replacements. Suspension and electrical problems are also fairly common. While some repairs are relatively minor, others can be quite expensive, making a thorough inspection and understanding of the vehicle’s history important before purchase.