2025 Chevrolet Express Cargo Service and Repair Manual

Few commercial vans have changed as little as the Express, and the 2025 Express Cargo carries on in 2500 and 3500 form on a 135-inch regular or 155-inch extended wheelbase, sold in a single WT grade. The standard 4.3L V6 is offered for gasoline or flex-fuel, and a 6.6L gasoline V8 is available for heavier loads, both with an eight-speed automatic. Because fleet vans often mix wheelbases and engines, this factory service and repair manual separates procedures, specifications, torque values and wiring diagrams by powertrain and chassis, with diagnostics and maintenance schedules suited to high-mileage working use.

Engines covered

• 4.3L V6 — OHV, naturally aspirated, gasoline
• 4.3L V6 — OHV, naturally aspirated, flex-fuel
• 6.6L V8 — OHV, naturally aspirated, gasoline

Body styles covered

• 4-door extended cargo van
• 4-door standard cargo van

Trims covered

• WT

Known issues on the 2025 Express Cargo. Four recalls are on federal record. The front passenger head restraint may have been improperly welded to the seat frame, raising injury risk in a crash. The impact beam in the driver's door may have improper welds and may not protect occupants as intended. A nut on the steering gear assembly may not have been tightened properly and could separate, causing loss of steering control. The fourth applies to cutaway versions, which may have been fitted with a tire that has sidewall damage and could lose air suddenly. No owner complaints are recorded. Seat, door, steering gear and wheel procedures in this manual include the torque values needed to inspect and correct each of these areas.