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2020 Chevrolet Express 3500

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By Research the Car 5 min read

Here’s a breakdown of common issues reported for the 2020 Chevrolet Express 3500, categorized by component and engine/transmission configuration.

The 2020 Chevrolet Express 3500 is a full-size van known for its utility and cargo capacity. Engine options include a 4.3L V6 producing 276 horsepower and 298 lb-ft of torque, and a 6.6L V8 producing 401 horsepower and 464 lb-ft of torque, and a 2.8L Duramax Diesel producing 181 horsepower and 369 lb-ft of torque. Transmission options typically consist of a 6-speed automatic transmission for the V6 engine, and a heavy-duty 6-speed automatic transmission for the V8 engine and 8-speed automatic transmission for the Diesel engine. Owners often appreciate the Express 3500 for its straightforward design, robust chassis, and suitability for commercial applications. Common dislikes include its outdated interior, fuel economy, and ride quality compared to newer vans.

Engine

4.3L V6

  • Oil Consumption
    • Description/Symptoms: Some owners report excessive oil consumption, requiring frequent oil top-offs between scheduled oil changes. Blue smoke may be visible from the exhaust.
    • Solution: In some cases, replacement of valve seals or piston rings may be necessary. A compression test can help determine the source of the oil consumption.
    • Estimated Cost to Fix: $1500 - $4000+ depending on the cause and repairs needed.
    • Recalls: None Found
  • Catalytic Converter Failure
    • Description/Symptoms: Check engine light, poor engine performance, rattling noise from under the vehicle.
    • Solution: Replace the faulty catalytic converter.
    • Estimated Cost to Fix: $800 - $1500+
    • Recalls: None Found

6.6L V8

  • Active Fuel Management (AFM) Lifter Failure
    • Description/Symptoms: Ticking or knocking noise from the engine, misfires, and potential engine damage.
    • Solution: Disable AFM or replace AFM lifters with standard lifters. Full engine rebuild may be necessary if significant damage occurred.
    • Estimated Cost to Fix: $2000 - $8000+ depending on the extent of the damage and chosen solution.
    • Recalls: None Found
  • Oil Leaks
    • Description/Symptoms: Oil spots under the vehicle, burning oil smell, low oil level. Common leak locations include the oil pan gasket, valve cover gaskets, and rear main seal.
    • Solution: Replace the leaking gasket or seal.
    • Estimated Cost to Fix: $200 - $1000+ depending on the location of the leak.
    • Recalls: None Found

2.8L Duramax Diesel

  • Diesel Exhaust Fluid (DEF) System Issues
    • Description/Symptoms: Check engine light related to DEF system, poor engine performance, reduced speed, messages indicating DEF quality or level problems.
    • Solution: Repair or replace faulty DEF sensors, DEF pump, or DEF injector. Flush the DEF system.
    • Estimated Cost to Fix: $300 - $1500+ depending on the component needing replacement.
    • Recalls: None Found
  • Fuel Injector Failure
    • Description/Symptoms: Rough idling, misfires, excessive black smoke from exhaust, reduced fuel economy.
    • Solution: Replace faulty fuel injectors.
    • Estimated Cost to Fix: $500 - $2000+ depending on the number of injectors needing replacement.
    • Recalls: None Found

Transmission

6-Speed Automatic (Paired with 4.3L V6)

  • Harsh Shifting
    • Description/Symptoms: Abrupt or jerky shifts between gears.
    • Solution: Perform a transmission fluid flush and filter change. Inspect valve body for wear or damage. Replacement of valve body may be necessary.
    • Estimated Cost to Fix: $200 - $1200+
    • Recalls: None Found
  • Torque Converter Failure
    • Description/Symptoms: Shuddering during acceleration, stalling, inability to shift properly.
    • Solution: Replace the torque converter.
    • Estimated Cost to Fix: $1000 - $2500+
    • Recalls: None Found

Heavy-Duty 6-Speed Automatic (Paired with 6.6L V8)

  • Delayed Engagement
    • Description/Symptoms: A noticeable delay when shifting into drive or reverse.
    • Solution: Check transmission fluid level and condition. Perform a transmission service, including filter replacement. In some cases, internal transmission damage may require a rebuild or replacement.
    • Estimated Cost to Fix: $150 - $4000+ depending on the severity.
    • Recalls: None Found

8-Speed Automatic (Paired with 2.8L Duramax Diesel)

  • Shifting Problems
    • Description/Symptoms: Hesitation shifting from park to drive, shuddering, jerking, harsh shifting.
    • Solution: Replacement of valve body.
    • Estimated Cost to Fix: $500 - $1500+
    • Recalls: None Found

Suspension

  • Leaf Spring Sagging/Failure
    • Description/Symptoms: Rear of the van sitting lower than normal, reduced load capacity, poor ride quality, squeaking noises.
    • Solution: Replace the leaf springs. Consider upgrading to heavier-duty springs if the van is frequently used for heavy loads.
    • Estimated Cost to Fix: $500 - $1500+ per side, depending on the type of springs used.
    • Recalls: None Found
  • Worn Ball Joints/Tie Rod Ends
    • Description/Symptoms: Clunking noises from the front suspension, loose steering, uneven tire wear.
    • Solution: Replace worn ball joints and/or tie rod ends. An alignment is recommended after replacement.
    • Estimated Cost to Fix: $200 - $800+ per side.
    • Recalls: None Found

Electrical

  • Battery Drain
    • Description/Symptoms: The battery drains quickly, especially when the vehicle is not in use.
    • Solution: Identify and repair the source of the parasitic draw. Common causes include faulty door switches, aftermarket accessories, or a failing alternator.
    • Estimated Cost to Fix: $100 - $500+ depending on the cause.
    • Recalls: None Found
  • Failing Sensors
    • Description/Symptoms: Check engine light, loss of performance
    • Solution: Replace the sensors
    • Estimated Cost to Fix: $50 - $300+
    • Recalls: None Found

Exterior

  • Sliding Door Issues
    • Description/Symptoms: Difficulty opening or closing the sliding side door, sticking, unusual noises.
    • Solution: Lubricate door tracks and rollers. Adjust or replace the door latch mechanism or rollers if necessary.
    • Estimated Cost to Fix: $50 - $500+ depending on the complexity of the repair.
    • Recalls: None Found

Interior

  • HVAC Blower Motor Failure
    • Description/Symptoms: Blower motor not working, weak airflow, unusual noises from the blower motor area.
    • Solution: Replace the blower motor. Check the blower motor resistor as well.
    • Estimated Cost to Fix: $150 - $500+
    • Recalls: None Found

Summary

The 2020 Chevrolet Express 3500, while a reliable workhorse, has several common issues to be aware of. Engine issues such as oil consumption and AFM lifter failure in the V8 can be costly to repair. Transmission problems range from harsh shifting to complete failure, depending on the transmission type. Suspension and electrical issues can also arise. The severity of these problems ranges from minor inconveniences to major repairs costing thousands of dollars. Prospective buyers should carefully inspect the vehicle’s maintenance history and consider a pre-purchase inspection by a qualified mechanic.

Chevrolet, Express 3500
Chevrolet Express 3500 2020
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