Chevrolet Express (1996–2002): How to Remove the Bumpers

Production Years and Place in the Chevrolet Lineup

The Chevrolet Express is a full-size van that debuted in 1996 as a replacement for the outdated Chevrolet Van (G-Series). Production of the first generation continued until 2002, after which the van underwent a redesign. The Express was Chevrolet’s response to the popular Ford E-Series and Dodge Ram Van, offering a more modern design and improved performance.

 

Model Names and Codes

The official model name is Chevrolet Express, but additional designations were used depending on the trim and market:

  • Chevrolet Express 1500 — the version with a gross weight of up to ½ ton.
  • Chevrolet Express 2500 and 3500 — reinforced versions for commercial use (¾ and 1 ton, respectively).
  • Chevrolet Express G1500/G2500/G3500 — an alternative designation in some catalogs (a legacy of the previous G-Van series).

Platform: GM GMT600 (shared with the GMC Savana).

 

Model Description

Design and Construction

The Chevrolet Express (1996–2002) featured a more angular body compared to the rounded shapes of its predecessor. The design was functional: flat panels simplified repairs, while the wide cargo door and low loading threshold made loading easier.

Engines

Depending on the year and trim, the following engines were available:

  • 4.3L V6 (L35) — the base engine with 200 hp, suitable for light loads.
  • 5.0L V8 (L30) — 230 hp, offering a good balance of power and fuel efficiency.
  • 5.7L V8 (L31) — 255 hp, the most popular option for heavy-duty tasks.
  • 6.5L V8 Turbodiesel — a diesel engine with 180–215 hp, available in commercial versions.

Transmission

  • 4-speed automatic 4L60E (for 1500 versions).
  • The more robust 4L80E (for 2500/3500).
  • 5-speed manual NV3500 (a rare option).

Suspension and Load Capacity

  • Front suspension: independent, torsion bar.
  • Rear suspension: leaf spring (2500/3500) or coil spring (1500).
  • Load capacity: from 1.2 tons (1500) to 3.5 tons (3500).

Trims

  • Base (Work Van) — minimal comfort, steel seats, no interior trim in the cargo area.
  • Passenger Van — a passenger version with 8–15 seats, improved sound insulation, and optional climate control.
  • Conversion Van — customized versions by third-party studios, featuring leather seats, TVs, and roof skylights.

 

Tools Required

For removal, you will need a set of socket wrenches and a sturdy breaker bar. It is advisable to treat all bolts and nuts with penetrating lubricant.

How to Remove the Front Bumper

  1. In the wheel arches, from underneath, unscrew one bolt on each side that secures the lower corners of the bumper to the brackets.
  2. (If present) Unscrew the front bolts securing the front part of the engine compartment shield.
  3. From underneath, unscrew the two long bolts that secure the bumper brackets to the frame rails.
  4. With an assistant, pull the bumper forward to remove it.

Chevrolet Express 1 Front Bumper Mounting Diagram

How to Remove the Rear Bumper

⇒Useful tips on how to remove the bumper and not break anything.⇐

  1. Disconnect the electrical connectors (if present).
  2. From underneath, unscrew the six nuts securing the rear bumper brackets to the frame rails.
  3. With an assistant, pull the bumper backward to remove it.

Chevrolet Express 1 Rear Bumper Mounting Diagram

Interesting Facts

  • Direct Competitor to the Ford E-Series — The Express was designed for the commercial market, where Ford dominated. Thanks to its more modern construction, it quickly gained popularity among freight companies.
  • Use in Law Enforcement — Due to its reliability and simplicity, the Express was often used by police, ambulances, and the military (including as a chassis for mobile command centers).
  • Longevity on the Assembly Line — Despite the 2003 redesign, the Express platform remained largely unchanged until the 2020s, a testament to its well-thought-out design.
  • Popularity as a Camper Van — Thanks to its sturdy frame, the Express became one of the most sought-after vans for conversion into motorhomes.
  • Rare Diesel Version — The 6.5L turbodiesel was not GM’s most successful engine but was valued for its fuel efficiency in commercial use.

 

Conclusion

The Chevrolet Express (1996–2002) was a significant milestone in the development of full-size vans by General Motors. Its simple and reliable construction, wide range of engines, and versatility made it popular among both commercial carriers and private owners. Despite its age, many of these vans remain on the road today due to their repairability and durability.