1996 CHEVROLET EXPRESS 1500 — Problems, Recalls & Safety Data

I WAS BRAKING WHILE EXITING THE FREEWAY AND LOST THE REAR BRAKES. AFTER AN INSPECTION, I FOUND THE BRAKE LINE BROKE ABOUT MIDWAY THROUGH THE CHASSE. I ALSO FOUND THAT THE BRAKE LINES WOULD CRACK WHERE EVER YOU BENT THEM. I HAD TO HAVE ALL THE BRAKE SYSTEM REPLACED BECAUSE OF CORROSION AT A COST OF $2143.00.

WIFE COMPLAINED OF PULSATING BRAKE PEDAL, TOOK VEHICLE FOR A SHORT TEST DRIVE, ON THE WAY BACK WHILE TRAVELING IN A STRAIGHT LINE AT APPROX. 30 MPH MADE A STOP APPLYING MODERATE PEDAL PRESSURE, BRAKE PEDAL WENT TO FLOOR. CAREFULLY DROVE THE REMAINING 1/8TH MILE HOME AND CRAWLED UNDERNEATH VAN. BRAKE LINES A MASS OF RUST, LINE THAT RUNS BACK ALONG LEFT SIDE RAIL FROM WHAT LOOKS LIKE AN ABS UNIT BURST UPON PEDAL APPLICATION AND WAS DRIPPING BRAKE FLUID, MASTER CYLINDER WAS ALMOST EMPTY UPON INSPECTION. THE MOST UNSAFE AND UNRELIABLE VEHICLE I HAVE EVER OWNED. AT 40,000 MILES A REAR LINE FROM THE PROPORTIONING VALVE ALSO RUSTED THROUGH BUT AT LEAST DID NOT BURST SUDDENLY, STARTED DRIPPING. IT AND THE 2 REAR WHEEL CYLINDERS WHICH WERE ALSO A MASS OF RUST NEEDED REPLACEMENT. *TR

TRANSMISSION SLIPS AND I RESEARCHED THE INTERNET AND THE 4L60E TRANSMISSION HAS A PROBLEM WHERE A WELD INSIDE THE TRANSMISSION GOES BAD AND MAKES THE TRANSMISSION FAIL. VAN WAS TAKEN TO A REPAIR SHOP AND REBUILT A FEW TIMES THE MECHANIC SAYS A NEW GM TRANSMISSION MUST BE PURCHASED AT $1,600 DOLLARS. *TR

96 CHEVY EXPRESS VAN, FAILED SIDE CARGO DOOR HINGES. THESE HINGES, PINS AND BUSHINGS, FAIL, SEIZE UP, AND THE SIDE CARGO DOORS ARE UNABLE TO BE OPENED. THIS MAKES IT UNSAFE FOR EXIT FROM THE VEHICLE FOR ANY PERSONS SITTING IN THE BACK OR REAR SEATS. GM KNOWS OF THIS PROBLEM. THERE ARE 4 SERVICE BULLETINS FOR THIS PROBLEM. DATED- SEPT. 24, 2001, MAY 01, 2002, JUNE 1, 2003, AND OCT 1, 2006... THE COST TO REPAIR THESE DOOR HINGES IS OUTRAGEOUS.. THEY ARE GM ONLY PARTS, AND TO REPLACE ALL 8 HINGES (THERE ARE 2 HINGES, BODY & DOOR, THAT MAKE UP 1 FULL HINGE. SO A TOTAL OF 8 ARE NEEDED TO REPLACE ALL) COST MINIMUM 115.00 A PIECE (SOME ARE MORE). THEN YOU ALSO HAVE TO REPLACE THE PINS AND BUSHINGS TO MAKE THE HINGES MOVE PROPERLY. THESE ARE 83.00 FOR JUST 2 PINS. SO TO DO ALL 4 HINGES YOU NEED 2 SETS. FOR A TOTAL TO COMPLETELY REPLACE ALL HINGES W/PINS AND BUSHINGS-- 1,036.00 JUST TO USE 2 DOORS ON YOUR VEHICLE. AND THAT ISN'T LABOR.. THIS IS OUTRAGEOUS.!!!!!!! THEY KNOW THIS IS A PROBLEM, AND THEY ARE KEEPING THE REPLACEMENTS TO THEMSELVES... MEANWHILE, I HAVE 2 DOORS ON MY VAN, THAT WON'T OPEN, SO IF I DO GET INTO AN ACCIDENT, MY CHILDREN WON'T BE ABLE TO GET OUT OF THE VEHICLE. THANKS GM.. *TR