VehicleVerdict

2009 Chevrolet Express 3500 problems

Verdict · NHTSA data

Limited data — recalls on file

NHTSA has just 11 complaints on file for the 2009 Chevrolet Express 3500 — too few to judge reliability from owner reports alone — but 2 recall campaigns apply to this year, so any used example should have its VIN checked for completed recall work.

11

NHTSA complaints

2

Recalls

0

Investigations

1

Crash-involved

0

Fires reported

0

Injuries

0

Deaths

—

NCAP overall

How does 2009 compare to other Express 3500 years?

Express 3500 NHTSA complaints by model year, 2009 highlighted26 complaints1997: 4 complaints1998: 4 complaints1999: 4 complaints2000: 4 complaints2001: 14 complaints2002: 3 complaints2003: 14 complaints2004: 18 complaints2005: 26 complaints2006: 17 complaints2007: 12 complaints2008: 12 complaints2009: 11 complaints2010: 5 complaints2012: 5 complaints2013: 1 complaints2014: 1 complaints2019: 3 complaints2021: 1 complaints2024: 4 complaints
Express 3500 NHTSA complaints by model year, 2009 highlighted. Red bars are years to avoid.

See all Express 3500 years to avoid →

What are the most common 2009 Chevrolet Express 3500 problems?

ComponentComplaintsShare
Fuel System327%
Electrical System218%
Tires & Wheels218%
Body & Structure19%
Other19%
Airbags19%
Speed Control19%

Does the 2009 Chevrolet Express 3500 have recalls?

2 NHTSA recall campaigns on file. Recall repairs are free at franchised dealers.

14V706000OtherNovember 5, 2014 · 34 units

Defect

Cummings Mobility Conversion & Supply (Cummings) is recalling certain model year 2006-2014 Ford E-150, E-250, E-350, Chevrolet Express, 2006-2008 Dodge Sprinter, and 2009-2014 Mercedes-Benz Sprinter, and 2013 Ford Transit Connect vehicles manufactured January 1, 2006, to October 8, 2014, equipped with certain model S2005, S2010, S5005, S5010, S5505, and S5510 wheelchair lifts manufactured by Ricon Corporation after January 1, 2006. The platform side plate of the affected wheelchair lifts may crack.

Consequence

If the platform side plates crack, the lift platform can separate from the lift and come to rest against the vehicle's lift door. When the doors are opened, the platform may fall out, increasing the risk of injury to the lift operator.

Remedy

Cummings will notify owners to take buses to a Ricon dealer or service center who will install supplemental platform support bumpers. Any platform that has already started cracking will be replaced, free of charge. The recall began January 13, 2015. Owners may contact Cumming's customer service at 1-800-639-5438 or Ricon customer service at 1-800-322-2884. Cumming's number for this recall is 14E-041.

09V456000Climate Control (A/C & Heat)November 19, 2009 · 269 units

Defect

CUES, INC. IS RECALLING CERTAIN MODEL YEAR 2007-2009 SERVICE VEHICLES BUILT ON VARIOUS CHASSIS EQUIPPED WITH CARRIER AIRV CEILING UNITS, MODEL NOS. 68RV0010BA, 68RV0012CA, AND 68RV0010EA. THE HEATER ELEMENT IN THESE ASSEMBLIES MAY BE DEFECTIVE WHICH COULD CAUSE THE UNIT TO CREATE SMOKE OR SPARKS.

Consequence

THIS DEFECT COULD RESULT IN A FIRE.

Remedy

CUES IS WORKING WITH CARRIER TO REMEDY THE AFFECTED VEHICLES. REPAIRS WILL BE MADE BY CARRIER FREE OF CHARGE. PLEASE SEE CARRIER'S DEFECT REPORT 09E-053. THE SAFETY RECALL BEGAN ON JANUARY 5, 2010. OWNERS MAY CONTACT CARRIER AT 1-877-584-7059 OR CUES AT 1-407-849-0190.

Consumer complaints filed with NHTSA

Representative excerpts, cleaned of personal information. These are consumer statements, not verified defects.

“CHEVY 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…”

Complaint filed with NHTSA · Fuel System · December 1, 2010

“I HAVE A 2009 CHEVROLET EXPRESS 3500 WITH 51,000 MILES ON IT. IN A TWO WEEK PERIOD AT THE END OF JAN '10 I HAD 3 TIRE VALVE STEM FAILURES. WHEN I ATTEMPTED TO REMOVE THE VALVE CAP TO CHECK AIR PRESSURE THE TOP OF THE STEM BLEW RIGHT OFF. I'VE REPLACED THREE AND THE ONE REMAINING FACTORY VALVE STEM…”

Complaint filed with NHTSA · Tires & Wheels · January 25, 2010

“TL* 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…”

Complaint filed with NHTSA · Electrical System · February 8, 2010

“TL* 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…”

Complaint filed with NHTSA · Airbags · July 10, 2015

“I TOOK THE VAN IN TO A DEALER TO FIND OUT WHY THE SERVICE AIR BAG LIGHT IS ON. AFTER PAYING $60.00 FOR A DIAGNOSTICS CHECK, (WHICH I STILL DON'T LIKE) THEY TOLD ME THE ROLLOVER SENSOR NEEDS TO BE REPLACED AT A CRIMINAL $700.00 WHICH I WILL NOT PAY. SOUNDS LIKE A GM ISSUE TO ME SO I CALLED THE HOT…”

Complaint filed with NHTSA · Other · July 10, 2015

2009 Chevrolet Express 3500 — common questions

Is the 2009 Chevrolet Express 3500 reliable?

The record is thin — 11 NHTSA complaints — so owner-report data can't strongly confirm reliability either way, though 2 recalls should be verified as completed.

What are the most common 2009 Express 3500 problems?

According to NHTSA complaint data, the leading problem areas are fuel system (3 complaints), electrical system (2 complaints), tires & wheels (2 complaints).

Does the 2009 Chevrolet Express 3500 have recalls?

Yes — NHTSA lists 2 recall campaigns affecting the 2009 Chevrolet Express 3500. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

Related

Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.

Compiled by Sharon Ben-Moshe, Founder.