Chevrolet Express (2003-2024): How to Remove the Bumpers

The second-generation Chevrolet Express is a full-size van that remains one of the most popular commercial and passenger vehicles in North America. The model has earned a reputation for being reliable, practical, and versatile, making it a top choice for both business users and large families.

Production Years and Names

The second-generation Chevrolet Express (sometimes referred to as Mk2) has been in production since 2003 and continues to this day (as of 2024). Unlike many other models, the Express has not undergone radical changes but has instead received gradual updates.

In different regions and trim levels, the model may be known under the following names:

• Chevrolet Express (base version)
• Chevrolet Express Cargo (cargo variant)
• Chevrolet Express Passenger (passenger minibus)
• Chevrolet Express Cutaway (chassis for customization)

Model Code

The second-generation platform carries the factory designation GMT610 (for all-wheel-drive modifications—GMT620). This platform is shared with the GMC Savana van, which is a twin of the Express with minor design and trim differences.

 

Model Description

Design and Construction

The Chevrolet Express Mk2 retains the classic layout of a full-size van with a front-engine configuration and rear- or all-wheel drive. The body-on-frame construction ensures high load capacity and towing capability.

The exterior design has seen several updates since 2003:

• 2003–2014: Rounded shapes typical of the early 2000s.
• 2015–present: More angular grille, new headlights, and bumpers.

Engines and Transmissions

Throughout its production run, the second generation has offered various powertrains:

Gasoline V8 engines:

• 4.8 L (285 hp)
• 5.3 L (300–355 hp)
• 6.0 L (342–360 hp)

Diesel option:

• 6.6 L Duramax V8 (260–445 hp, depending on the year)

Transmissions—4- or 6-speed automatic (6L90, 8L90 in later versions).

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Note: Depending on the production year, mounting points may vary slightly.

How to Remove the Front Bumper

1. In the wheel arches, unscrew one bolt on each side that secures the bumper to the brackets (or remove the bolts attaching the brackets to the body).
2. Unscrew two bolts (fastened from top to bottom) that secure the bumper to the frame rails (these can be accessed from underneath without removing the radiator grille).
3. With an assistant, pull the bumper forward to remove it.

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How to Remove the Rear Bumper

1. If equipped, disconnect the electrical connectors.
2. From underneath, unscrew eight nuts (four on each side) securing the brackets to the body.
3. With an assistant, pull the bumper backward to remove it.

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Capacity and Body Styles

• Cargo version: Up to 4.6 m³ of cargo space, payload capacity up to 2.7 tons.
• Passenger version: Up to 15 seats (including the driver).
• Cutaway: Chassis for conversion into campers, buses, or special-purpose vehicles.

 

Interesting Facts

Longevity in the Market

The second-generation Chevrolet Express is one of the longest-produced vans in history. Since 2003, its design has remained largely unchanged, a testament to the well-thought-out original platform.

Popularity Among Emergency Services

Thanks to its reliability and ease of maintenance, the Express is used by police, ambulance services, and the military in the U.S. and other countries.

Electric Version

In 2023, General Motors announced the Chevrolet Express EV, an electric van set to replace the gasoline model in the coming years.

Competitor to the Ford E-Series

For decades, the Chevrolet Express has competed with the Ford E-Series (formerly Econoline). Despite more modern rivals (Ford Transit, Mercedes Sprinter), the Express remains popular due to its simplicity and low maintenance costs.

High Mileage Records

It is not uncommon for the Chevrolet Express Mk2 to exceed 500,000 km without an engine overhaul, especially in diesel versions.

 

Conclusion

The second-generation Chevrolet Express is a prime example of a successful combination of reliability, practicality, and affordability. Despite its conservative design, it remains in demand due to its versatility. With the introduction of the electric version, GM aims to preserve the model’s legacy while adapting it to modern requirements.