1996 Chevrolet Express 1500 Service and Repair Manual
This factory service and repair manual for the 1996 Chevrolet Express 1500 has three gasoline engines to sort between: a 4.3L V6 of 262 cubic inches and two naturally aspirated V8s, the 5.0L of 305 cubic inches and the 5.7L of 350. Both bodies are three-door, one built out as a cargo van and one as a passenger van, and equipment divides only two ways, Base and LS. The engine chapters branch by displacement; the chassis, brake and body sections apply to every van described here.
Engines covered
- 5.0L V8 (305 cu in) — OHV, naturally aspirated, gasoline
- 4.3L V6 (262 cu in) — OHV, naturally aspirated, gasoline
- 5.7L V8 (350 cu in) — OHV, naturally aspirated, gasoline
Body styles covered
- 3-door standard cargo van
- 3-door standard passenger van
Trims covered
- Base
- LS
Known issues on the 1996 Express 1500. Owners have logged just four complaints against this model year, and they scatter rather than pile up: two on the service brakes, one on the power train, one on the body structure. That is a thin record to diagnose from, which is the argument for working off specifications instead of anecdotes. The manual gives brake hydraulic and friction material dimensions, transmission and axle procedures with their torque values, and the body and frame sections that a fit or corrosion complaint would send a technician to.
This warranty administration bulletin provides information regarding the field action courtesy transportation policy.
Expanded Availability for Remanufacture and Return (R&R) Electronic Control Modules
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 LIN
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 PE
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 TAK
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 EX
