2022 Chevrolet Express 3500

The 2022 Chevrolet Express 3500 is a full-size van primarily used for commercial purposes, offering substantial cargo and passenger space. It comes with three engine options: a 4.3L V6 (276 hp, 298 lb-ft of torque), a 6.6L V8 (401 hp, 464 lb-ft of torque), and a 2.8L Duramax Turbo-Diesel Inline-4 (181 hp, 369 lb-ft of torque). The 4.3L V6 is paired with an 8-speed automatic transmission while the 6.6L V8 and the 2.8L Duramax are paired with a 6-speed automatic transmission. Owners often appreciate the Express 3500 for its payload capacity, simple design and aftermarket support. However, some dislike its outdated design, poor fuel economy, and basic interior features.

Engine

4.3L V6

• Engine Misfires
  • Description/Symptoms: Rough idling, check engine light illuminated, loss of power, and diagnostic codes indicating misfires on specific cylinders. This can be caused by worn spark plugs, faulty ignition coils, or fuel injector issues.
  • Solution: Replace spark plugs, ignition coils, or fuel injectors as needed. Diagnose and repair any vacuum leaks that may be causing the misfire.
  • Estimated Cost to Fix: $100 - $500+
  • Recalls: None Found

6.6L V8

• Oil Leaks
  • Description/Symptoms: Oil spots under the vehicle, burning oil smell, low oil level, and visual inspection revealing oil leaks from valve cover gaskets or oil pan gasket.
  • Solution: Replace the leaking valve cover gaskets or oil pan gasket.
  • Estimated Cost to Fix: $200 - $800+
  • Recalls: None Found
• Check Engine Light due to EVAP System
  • Description/Symptoms: The check engine light is illuminated due to a malfunctioning EVAP system. This is generally due to a faulty gas cap, broken/cracked hoses, or a bad EVAP purge valve.
  • Solution: Diagnose the exact cause of the EVAP system failure and replace the applicable parts.
  • Estimated Cost to Fix: $50 - $300+
  • Recalls: None Found

2.8L Duramax Turbo-Diesel Inline-4

• Diesel Particulate Filter (DPF) Issues
  • Description/Symptoms: Reduced engine power, check engine light, and codes related to the DPF being clogged. This can result from frequent short trips that prevent the DPF from properly regenerating.
  • Solution: Forced DPF regeneration, or replacement if necessary. Adjust driving habits to include longer trips that allow for proper regeneration.
  • Estimated Cost to Fix: $200 - $2000+ (DPF replacement)
  • Recalls: None Found

Transmission

6-Speed Automatic (paired with 6.6L V8 and 2.8L Duramax)

• Harsh Shifting
  • Description/Symptoms: Noticeable clunking or jerking during gear changes, especially when shifting between 1st and 2nd gear or 2nd and 3rd gear.
  • Solution: Transmission fluid flush, valve body inspection and repair/replacement, or complete transmission rebuild.
  • Estimated Cost to Fix: $150 - $3500+
  • Recalls: None Found

8-Speed Automatic (paired with 4.3L V6)

• Torque Converter Shudder
  • Description/Symptoms: A vibration or shudder felt while driving at steady speeds, typically between 30-50 mph. This can be caused by degradation of the transmission fluid or wear in the torque converter.
  • Solution: Perform a transmission fluid flush with the updated fluid specification, reprogram the transmission control module (TCM), or replace the torque converter if the issue persists.
  • Estimated Cost to Fix: $150 - $1500+
  • Recalls: None Found

Suspension

• Rear Leaf Spring Sagging
  • Description/Symptoms: Rear of the van sitting lower than normal, especially when loaded. Reduced ride quality and handling.
  • Solution: Replace the rear leaf springs. Consider aftermarket heavy-duty leaf springs for increased load capacity.
  • Estimated Cost to Fix: $500 - $1500+
  • Recalls: None Found

Electrical

• Battery Drain
  • Description/Symptoms: Vehicle hard to start or dead after sitting for a short time. Can be caused by parasitic drain from an accessory or faulty module.
  • Solution: Diagnose and repair the source of the parasitic drain. Ensure the battery is in good condition and replace if necessary.
  • Estimated Cost to Fix: $100 - $500+
  • Recalls: None Found
• Infotainment System Freezing/Crashing
  • Description/Symptoms: The infotainment screen freezes, becomes unresponsive, or crashes intermittently.
  • Solution: Update the infotainment system software. If the problem persists, replace the head unit.
  • Estimated Cost to Fix: $0 - $800+
  • Recalls: None Found

Exterior

• Sliding Door Issues
  • Description/Symptoms: Difficult to open or close the sliding door, especially on uneven surfaces. The rollers, hinges, or tracks can become misaligned or worn.
  • Solution: Adjust or replace the rollers, hinges, or tracks. Lubricate moving parts.
  • Estimated Cost to Fix: $50 - $500+
  • Recalls: None Found

Interior

• HVAC Blower Motor Failure
  • Description/Symptoms: The HVAC blower motor stops working, resulting in no air flow from the vents. Can be caused by a faulty blower motor, resistor, or wiring issue.
  • Solution: Replace the blower motor, resistor, or repair any wiring problems.
  • Estimated Cost to Fix: $100 - $400+
  • Recalls: None Found

Summary

The 2022 Chevrolet Express 3500 can have a range of issues, from minor electrical glitches and door problems to more significant engine and transmission concerns. The severity of these issues ranges from simple fixes to more expensive repairs. Careful maintenance and prompt attention to symptoms can help mitigate potential problems. It’s worth noting that the V8 engines appear to have issues with oil leaks, while the diesel engine has issues with the DPF. The 8-speed transmission appears to have torque converter shudder issues, while the 6-speed transmission has harsh shifting issues.