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Chevy Express/GMC Savana

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What is this discussion about? Chevrolet Express, GMC Savana, Chevrolet Express Cargo, Chevrolet Sportvan, Chevrolet Chevy Van, Chevrolet Chevy Van Classic, Van

#349 of 595 The answers to your transmission problems by knucklebanger Oct 01, 2003 (7:49 pm)
I just traded in my '97 Chevy Express Van on a new '03 Express. I also own a '97 GMC Sierra. Both '97 trucks had the same powertrains. Both had the transmission failures described throughout this board. Both caused me lots of frustration trying to figure out why these problems were occurring.   It turned out to be two problems: One is in the valve body, the other is a stamped metal part referred to as the "sun shell" that carries torque in 4th, 2nd, and reverse.   In 1993, the 4L60 transmission was introduced as the 4L60E (E=electronic controlled) with a new aluminum valve body. Previous versions of the transmissions used cast iron valve bodys that were absolutely bullet-proof. I don't know all the reasons for the change, but have to think it was to save weight. In any event, the Torque Converter Clutch Valve (TCC) had a tendency in the 96-98 transmissions to wear the bore it slides back and forth in. The round hole would become slightly oblong, allowing trans fluid to leak past the valve resulting in loss of pressure to the Torque Converter lock-up circuit. What happens next is that the PCM, sensing slippage commands maximum line pressure, which results in the hard shift many here complain of.   Interestingly, the hard shift is actually a good thing. It helps prevent the clutches from slipping as they engage by applying the extra fluid pressure so that they engage quicker with less slip. However, if not corrected, the slippage will lead to burning up the torque converter.   The fix is to resleeve the TCC bore and install a new TCC valve. Sonnax makes a kit and sells a special reamer to do this. The kit costs $40-65, and the reamer around $75. The whole job can be done in a few hours. Sonnax has a web site, and are good about providing information on their kits. There are also some good technical papers available at the site as well.   The other problem happened to my pick-up truck at around 68K miles, and to my Van at 72k miles. What happens is you lose 2nd, 4th and Reverse gears, probably experience a big "Clunk" sound. The problem is a basket shaped sheet metal stamping that carries load in 4th, 2nd, and Reverse. There's a splined flange that is spin welded onto the bottom of the basket that transfers torque from the sun shell into the output shaft. After 60000 miles or so, the flange fatigues and the spin-weld fails.   The sun shell has been a marginal part of the 4L60E, as well as it's predecessor models, the 4L60 and the 700R transmissions for a long time. It just became a chronic problem when the company started mating the 4L60E to the higher output Vortec engines beginning in 1996.   Hope this helps.
#350 of 595 One more thing by knucklebanger Oct 01, 2003 (7:52 pm)
If you experience the sun shell failure as described above, have your trans rebuilt with a beefier aftermarket part. One that is available is called the "Beast". I've seen them sold at Transmission parts dealers. They're much heavier-duty than the OEM ones.
#351 of 595 thanks mrh3108-Some Questions by BOBPUT Oct 13, 2003 (9:55 pm)
I just bt 99 Savana Hi-top after 4 yrs leased (58K miles)-Agree with gd reliability (replacement tires-Dunlops had 4/4 failures! tread sep-only major problem) Are you still on OE battery? What mileage on front(repl 30k)/rear brakes? About to do major maintenance (2 yr) -any particular suggestions from your experience?? Thanks BOBPUT in Tampa
#352 of 595 2001 express cargo van by trolloc Nov 07, 2003 (10:08 pm)
Im researching buying a 2001 Express cargo van with the v6 engine...ive found little in the way of reviews, but JD Power gives it some low ratings. I was hoping for some specific feedback to help me make my decision...any comments are appreciated...thanks.   trolloc
#353 of 595 by ssack Nov 10, 2003 (5:22 pm)
I have a 2001 Savana that has 18xxx miles on it and I have not had any real problems to be concerned about. We took it on vacation this summer and travelled about 4000 miles problem free. I also use it to haul all kinds of stuff from the kids to building supplies and have found it to be one of the most reliable vehicles I have ever owned. I absolutely love it. Don't judge the vehicle by the negative complaints, there are a multitude of positives you just dont hear about.
#354 of 595 Transmission upgrade by peter2494 Nov 14, 2003 (2:38 pm)
I've a 98 savana with 4L60E transmission. Can I replace the 4L60E with the 4L80 without any major modification to the van? Thanks
#355 of 595 Re: Not starting after rain (#338 - Kasiekelly) by btrust Nov 28, 2003 (10:39 pm)
Fought similar problem for months in '91 Chevy Suburban, w/ several tows and only speculative problems found at shop. I found that pulling up the engine harness as it runs across firewall was a temporary fix - was shorting when wet in hidden area between bellhousing and body sheetmetal. (No need for a hard short - just a water path alone apparently conducts enough to confuse engine control electronics). I removed harness and found insulation breaks from rubbing against edge; split into 2 smaller cables and retaped. No problems since. Water short could be somewhere else in your case, probably away from direct engine heat. While cranking, and avoiding personal injury, try moving cable in various places with a wooden stick, or go along the cabling with compressed air to locate bad insulation.
#356 of 595 Owner experience with 2003 Express by fdm2000 Dec 08, 2003 (8:19 am)
I'm looking at purchasing a new 2003 Express conversion van and wondered what experiences - pro and con that others have had with this van.It has the 6 cyl engine.   Any comments - suggestions - caveats etc would be appreciated.   Frank
#357 of 595 1993 Chevy Van Stealth ABS valve by lovethevan Dec 12, 2003 (5:05 pm)
This Chevy has 100,000 miles and no unscheduled maintenance. While driving on a dirt road about 35 mph, the brake pedal went to the floor and the ABS alarm light came on, then the BRAKE light on the dashboard came on. The brakes were soft but held sufficiently to get a dealer's opinion that it was an ABS valve failure with a large price tag. Has anyone had this type of brake failure on this van?
#358 of 595 Conversion by johnering Dec 27, 2003 (5:47 pm)
I'm considering a full size coversion van but I can't seem to find much info regarding safety, reliability. Neither Consumer Reports nor NHTSA have any information, but here on Edmunds haven't found advice regarding aftermarket production quality and pricing seems all over the board.   Email: johneringhotmail.com

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