According to Au7o's analysis of 770+ owner reports, the 2009 GMC Savana has 10 documented known issues, with 5 rated critical. The most serious are Fuel Pump Module Failure and Hard Start / Stalling ($350-$900 repair), Brake Line Corrosion and Brake Fluid Loss (Rust Belt) ($600-$2,000 repair), Cutaway Rear HVAC Blower Circuit Corrosion at Left B-Pillar - Fire Risk (Recall 23V-247) ($0-$0 repair), 4L80E/4L85E Harsh or Delayed Shifts, TCC Shudder and Loss of Forward/Reverse (Savana 2500/3500) ($350-$4,500 repair) and 4L60E/4L65E Automatic Transmission 3-4 Clutch Pack Burnup and Overdrive Slip (Savana 1500) ($1,800-$3,200 repair). The most commonly reported issue is Fuel Pump Module Failure and Hard Start / Stalling with 430 owner reports. Across all issues with published estimates, repair costs range from $50 to $5,000. DIY maintenance guides at au7o.io.
POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE:SOFTWARE
General Motors, LLC (GM) is recalling certain 2022-2023 Chevrolet Express and GMC Savana vehicles. Incorrect software in the transmission control module (TCM) may result in harsh shifting, reduced power, unintended deceleration, rear wheel lockup, or cause the vehicle to move in an unintended direction.
Campaign #24V83900007/11/2024
ELECTRICAL SYSTEM:WIRING
General Motors, LLC (GM) is recalling certain 2003-2023 Chevrolet Express Cutaway and GMC Savana Cutaway incomplete vehicles equipped with wiring for an optional rear heating, ventilation, and air-conditioning (HVAC) system. When the HVAC blower motor circuit is left unused with exposed connectors and wiring, the circuit can corrode and overheat.
Campaign #23V24700006/04/2023
TIRES
General Motors LLC (GM) is recalling certain 2020 Buick Enclave, Cadillac XT4, XT5, Escalade, Escalade ESV, Chevrolet Suburban, Tahoe, Traverse, GMC Yukon, Yukon XL, 2018-2021 Chevrolet Express, GMC Savana, 2019-2020 Chevrolet Blazer, Silverado 1500, GMC Acadia, Sierra 1500, and certain Continental tires sold to the aftermarket for various model year 2018-2021 vehicles. The affected tires were cured for too long during production.
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According to Au7o's analysis of 770+ owner reports, the 2009 GMC Savana has 10 documented issues. The most frequently reported are: Fuel Pump Module Failure and Hard Start / Stalling, Brake Line Corrosion and Brake Fluid Loss (Rust Belt), Cutaway Rear HVAC Blower Circuit Corrosion at Left B-Pillar - Fire Risk (Recall 23V-247). Of these, 5 are rated critical and should be addressed promptly.
Is the GMC Savana reliable?
The 2009 GMC Savana has 10 known issues documented across 770+ owner reports. 5 issues are rated critical: Fuel Pump Module Failure and Hard Start / Stalling and Brake Line Corrosion and Brake Fluid Loss (Rust Belt) and Cutaway Rear HVAC Blower Circuit Corrosion at Left B-Pillar - Fire Risk (Recall 23V-247) and 4L80E/4L85E Harsh or Delayed Shifts, TCC Shudder and Loss of Forward/Reverse (Savana 2500/3500) and 4L60E/4L65E Automatic Transmission 3-4 Clutch Pack Burnup and Overdrive Slip (Savana 1500). Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
How much does it cost to fix common GMC Savana problems?
Repair costs for known GMC Savana issues range from $0 to $5,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Fuel Pump Module Failure and Hard Start / Stalling, typically costs $350-$900 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
What is the 2003-2020 GMC Savana Fuel Pump Module Failure and Hard Start / Stalling?
The GMC Savana (and Chevrolet Express) fuel pump module is known for premature failure between 80,000-140,000 miles, often stranding drivers without warning. The in-tank electric fuel pump motor burns out or the sending unit becomes erratic. Running the tank consistently below 1/… Repairs typically run $350-$900. Severity: high.
What is the 2003-2014 GMC Savana Brake Line Corrosion and Brake Fluid Loss (Rust Belt)?
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.
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On the 1996-2009 GMC Savana, the heavy-duty 4L80E (4L85E behind the 8.1L and the diesel) fitted to Savana 2500 and 3500 vans develops a distinct failure set from the 1500's 4L60E. Owners report shuddering around 45 mph as the torque converter clutch tries to lock, hard or late shifts, no downshift on throttle demand, and in advanced cases the van reaching operating temperature and then behaving as though it is in neutral in every gear. Root causes documented on 3500 vans include a failed TCC PWM solenoid or its electrical circuit, worn valve body bores, and pressure loss from a worn pump. Commercial-fleet duty cycles - constant loaded stop-and-go, cutaway upfit weight at the top of the GVWR - accelerate all of it.
No recall. GM bulletin 08-07-30-001 covers 4L80E harsh/delayed shifts, slipping and no forward/reverse. Diagnose electrically first: a TCC PWM solenoid or its wiring is a comparatively cheap repair ($350-$700) and P1860 points straight at it. If pressure tests show pump or valve body wear, or the van has lost gears, the fix is a rebuild or reman unit at roughly $2,500-$4,500 installed for a 3500. On any van used as a work truck, fit an auxiliary cooler and service the fluid every 50,000 miles rather than following the severe-service book interval.
On the 1996-2014 GMC Savana, the light-duty Savana 1500 uses the 4L60E (later 4L65E) four-speed, not the heavy-duty 4L80E fitted to 2500/3500 models, and it is the weak link of the lineup. In van duty the converter clutch and overdrive cycle constantly at city speeds, and the 3-4 clutch pack and its apply seals cook. Owners describe a van that drives normally for a few miles and then flares between 3rd and 4th, or revs like it is in neutral once hot. Forum reports on 1996-2002 5.0L/5.7L and 2003-2014 5.3L 1500 vans repeat the same pattern; a plugged filter and burned fluid are usually found at teardown. This is a 1500-specific chapter - it is not the 4L80E story and should not be read across to the 2500/3500.
No recall or GM special coverage exists. The real fix is a rebuild or reman 4L60E/4L65E with upgraded 3-4 clutch pack (more frictions, updated apply piston) and a new torque converter; a shop rebuild typically runs $1,800-$3,200 installed. Preventively, shorten the fluid-and-filter interval to roughly 50,000 miles and add an auxiliary transmission cooler - van duty cycles run the fluid far hotter than the truck the box was calibrated for. Early slip caught with only a plugged filter has occasionally been cured with a fluid and filter service, but once the 3-4 pack is burned only a rebuild corrects it.
On the 2003-2023 GMC Savana, savana Cutaway chassis are built with an unused wiring circuit at the lower left B-pillar so that a final-stage upfitter can install an optional rear HVAC blower. When the upfitter leaves that circuit's connectors or cut wire ends unsealed, moisture and road contamination corrode the terminals over time. The corroded joint develops high resistance, draws excessive current, and can overheat enough to start a fire at the B-pillar. GM's field analysis identified eight related complaints, six of them alleging fires, with notice dates spanning 2018 to 2022. GM recalled 149,028 cutaways in April 2023 under NHTSA campaign 23V-247 (GM number N222386050); 10,440 of those were GMC Savana Cutaways and the balance were Chevrolet Express Cutaways, so this genuinely names the Savana rather than being an Express-only campaign. Build range: May 2002 through March 2023.
Common Symptoms
Burning or melted-plastic smell near the left B-pillar
Smoke from the lower left interior wall
Rear blower inoperative or intermittent
Blown fuses on the rear HVAC circuit
Fire at the lower left side of the body
How to Fix
Free recall remedy under NHTSA 23V-247 / GM N222386050: the dealer seals the rear HVAC blower motor circuit at the left B-pillar so the high-current-draw condition cannot develop. Owners of any 2003-2023 Savana Cutaway - especially ambulance, shuttle, box and RV upfits - should run the VIN at NHTSA.gov/recalls, because cutaway chassis frequently change hands as commercial equipment and recall notices do not follow them. If an upfitter has since added rear HVAC, have the connections inspected for corrosion at the same visit.
On the 1996-2014 GMC Savana, the ignition switch (electrical portion, not the lock cylinder) develops worn contacts, causing intermittent no-start, stalling while driving, or loss of electrical accessories. A well-known issue shared with the Chevy Express.
Replace the ignition switch assembly (ACDelco D1432D). The switch is located on the steering column behind the dash. This is the electrical switch, not the key cylinder. Relatively straightforward replacement.
On the 2003-2020 GMC Savana, the GMC Savana (and Chevrolet Express) fuel pump module is known for premature failure between 80,000-140,000 miles, often stranding drivers without warning. The in-tank electric fuel pump motor burns out or the sending unit becomes erratic. Running the tank consistently below 1/4 generates heat that shortens pump life. Commercial use Savanas that frequently run low on fuel — common in fleet operations — see pump failures well before 80,000 miles. The fuel pump is a demanding repair requiring tank removal on the Savana.
Hard start or extended cranking before engine fires
Engine stalls at idle and won't restart when hot
Fuel pressure below specification (should be 55-60 psi)
Engine stumbles and hesitates under load
No-start condition with no fuel pressure
Fuel gauge erratic or reads wrong
How to Fix
Replace fuel pump module (ACDelco MU1374 for 6.0L Savana, MU1373 for 4.8L). Keep fuel tank above 1/4 full at all times. For fleet vehicles, replace pump proactively at 100,000 miles. Aftermarket Walbro or Delphi pumps are common alternatives.
High Confidence430 owner reportsLast reported by owners Feb 2026Reviewed Feb 2026
Community reported
340 owners
On the 2003-2014 GMC Savana, the 2003-2014 GMC Savana uses steel brake lines that are subject to severe corrosion in salt-belt states. The factory lines corrode from the outside in and can rupture without warning, causing catastrophic brake failure. This is the same safety-critical issue as documented across all GM full-size truck/van platforms of the same era. Commercial Savanas that operate year-round in Northern states, where road salt is used heavily, are at highest risk. NHTSA has received hundreds of complaints on brake line corrosion leading to loss of braking ability.
Brake fluid level dropping with no external wheel leak
Visible rust or corrosion on brake lines under vehicle
Brake pedal traveling to floor
Brake warning light
Complete loss of braking after line rupture
How to Fix
Inspect all brake lines annually in rust-belt states. Replace corroded lines with Dorman stainless steel pre-bent replacement sets. Consider full brake line replacement as preventive maintenance at 100,000+ miles on any Savana that has lived in salt-belt states.
High Confidence340 owner reportsLast reported by owners Feb 2026Reviewed Feb 2026
On the 1996-2018 GMC Savana, savana and Express bodies rot in a predictable pattern: rocker panels beneath the front and sliding doors, the bottoms of the doors themselves, the lower rear quarters at the wheel arches, and the lower skins of the side cargo and rear doors. The doors rust from the inside out - water passes the weatherstrip, pools in the door bottom because the drains silt up, and by the time paint bubbles appear there is substantial metal loss behind it. Owners on van forums identify a specific aggravating design detail: where running boards are fitted, the assembly traps water, mud and road salt between the steel rocker panel and the fiberglass upper cladding, holding the rocker permanently wet. On a rust-belt commercial van this becomes structural, not cosmetic - the rocker is what the sliding door track and body mounts rely on.
Common Symptoms
Paint bubbling along the rocker panel below the doors
Rust holes at the bottom of the front or sliding doors
Perforation at the rear wheel arch
Water or debris packed behind running board cladding
Sliding door track loose or misaligned
Rust visible on the lower rear cargo door skins
How to Fix
No recall or corrosion warranty extension. Catch it early: clear the door drain holes at every service, and if the van has running boards, remove them periodically and clean out the packed debris between the rocker and the cladding. Once metal is perforated the fix is cut-and-weld with reproduction panels - outer rocker panels, lower door skins and wheel arch repair panels are all available for 1996-2018 vans and are e-coated for corrosion protection. Budget $400-$900 per rocker at a body shop and $300-$700 per lower door skin; both sides plus quarters on a badly rusted van easily reaches $3,000-$5,000. Bolt-on cover panels glued over rusted metal hide the problem and accelerate it.
On the 1996-2025 GMC Savana, the rear cargo doors and sliding side door hinges wear out from the weight of the doors and constant commercial use. Doors sag, become difficult to close, and the weatherstripping no longer seals properly.
Replace door hinge pins and bushings, or complete hinge assemblies if worn beyond bushing repair. Adjust door striker plates after hinge repair. Lubricate all hinge pivot points with white lithium grease every 6 months.
On the 1999-2020 GMC Savana, on the 4.8L, 5.3L and 6.0L Vortec V8s the exhaust manifold bolts - almost always the ones at the extreme front and rear of each cylinder head - snap from repeated thermal cycling, letting the manifold lift off the head. The classic symptom is a loud tick or 'exhaust leak' ticking at cold start that quiets as the engine expands and seals the gap. It is common enough on Savana and Express vans that fleet operators running 6.0L passenger vans report the front and rear bolts broken on both banks across their whole fleet. What makes this a van-specific problem rather than a generic truck one is access: the engine sits in a doghouse inside the cab, so the rear bolt near the firewall is extremely difficult to reach and the labor bill is far higher than on a Silverado with the same engine.
Loud ticking at cold start that fades as engine warms
Exhaust smell in cabin
Ticking that gets louder under acceleration
Soot streaks at the cylinder head/manifold joint
Failed emissions or O2 sensor codes from unmetered air
How to Fix
No recall. Correct repair is to extract the broken bolt stubs (drill and easy-out, or weld a nut to the stub), replace all manifold bolts with the updated design, and fit new manifold gaskets. On a van expect $600-$1,500 per side because of doghouse access - considerably more than the same job on a pickup. Manifold repair clamps that bridge a broken bolt are sold as a fix but are a temporary measure only. Inspect for a cracked manifold at the same time; a cracked casting ticks identically and must be replaced.
On the 1996-2014 GMC Savana, savana V8s develop intake manifold gasket leaks that show up either as an external drip - usually coolant down the driver's side of the block, or oil at the rear of the valley - or, worse, as an internal leak that lets coolant into the oil. Owners of 6.0L vans report antifreeze appearing on the driver's side with no hose failure to explain it; the same failure is documented on the earlier 5.7L and 7.4L Vortec engines. Left alone the loss of coolant leads to overheating, and a coolant-into-oil leak destroys bearings. Because the engine lives under the doghouse, the leak often shows up as coolant smell in the cab before a puddle appears under the van.
Common Symptoms
Coolant leak down the side of the engine block
Low coolant with no visible hose failure
Coolant smell inside the cab
Milky oil or oil in the coolant
Overheating
Rough running or misfire from a vacuum leak
How to Fix
No recall. Replace the intake manifold gasket set - upper and lower where applicable - using the updated GM gaskets and correct torque sequence; expect roughly $1,000-$1,400 on a Savana 1500/2500 including labor, with the doghouse removal driving most of the cost. Pressure-test the cooling system to confirm the intake gasket rather than a weeping water pump or heater line before committing. If coolant has entered the oil, change oil and filter immediately after the repair and re-check after a short interval. Note that repeat failures years later are reported, so use OE-quality gaskets, not the cheapest set.
General Motors, LLC (GM) is recalling certain 2021 Chevrolet Express and GMC Savana vehicles equipped with 6.6L gasoline engines. The positive battery cable terminals may contact a fuse block assembly attachment post and cause an electrical short circuit.
Campaign #21V18900018/03/2021
STRUCTURE:BODY:DOOR
General Motors LLC (GM) is recalling certain 2025 Chevrolet Express and GMC Savana vans. The impact beam located in the driver's side door may have improper welds.
The 2003-2014 GMC Savana uses steel brake lines that are subject to severe corrosion in salt-belt states. The factory lines corrode from the outside in and can rupture without warning, causing catastrophic brake failure. This is the same safety-critical issue as documented across… Repairs typically run $600-$2,000. Severity: high.
What is the 2003-2023 GMC Savana Cutaway Rear HVAC Blower Circuit Corrosion at Left B-Pillar - Fire Risk (Recall 23V-247)?
Savana Cutaway chassis are built with an unused wiring circuit at the lower left B-pillar so that a final-stage upfitter can install an optional rear HVAC blower. When the upfitter leaves that circuit's connectors or cut wire ends unsealed, moisture and road contamination corrode… Repairs typically run $0-$0. Severity: high.
What is the 1996-2009 GMC Savana 4L80E/4L85E Harsh or Delayed Shifts, TCC Shudder and Loss of Forward/Reverse (Savana 2500/3500)?
The heavy-duty 4L80E (4L85E behind the 8.1L and the diesel) fitted to Savana 2500 and 3500 vans develops a distinct failure set from the 1500's 4L60E. Owners report shuddering around 45 mph as the torque converter clutch tries to lock, hard or late shifts, no downshift on throttl… Repairs typically run $350-$4,500. Severity: high.
What is the 1996-2014 GMC Savana 4L60E/4L65E Automatic Transmission 3-4 Clutch Pack Burnup and Overdrive Slip (Savana 1500)?
The light-duty Savana 1500 uses the 4L60E (later 4L65E) four-speed, not the heavy-duty 4L80E fitted to 2500/3500 models, and it is the weak link of the lineup. In van duty the converter clutch and overdrive cycle constantly at city speeds, and the 3-4 clutch pack and its apply se… Repairs typically run $1,800-$3,200. Severity: high.
What is the 1996-2014 GMC Savana Ignition Switch Electrical Failure?
The ignition switch (electrical portion, not the lock cylinder) develops worn contacts, causing intermittent no-start, stalling while driving, or loss of electrical accessories. A well-known issue shared with the Chevy Express. Repairs typically run $50-$250. Severity: medium.
What is the 1999-2020 GMC Savana Broken Exhaust Manifold Bolts on Gen III/IV Vortec V8 Causing Cold-Start Tick and Exhaust Leak?
On the 4.8L, 5.3L and 6.0L Vortec V8s the exhaust manifold bolts - almost always the ones at the extreme front and rear of each cylinder head - snap from repeated thermal cycling, letting the manifold lift off the head. The classic symptom is a loud tick or 'exhaust leak' ticking… Repairs typically run $600-$2,200. Severity: medium.
What is the 1996-2018 GMC Savana Rocker Panel, Lower Door and Wheel Arch Rust-Through?
Savana and Express bodies rot in a predictable pattern: rocker panels beneath the front and sliding doors, the bottoms of the doors themselves, the lower rear quarters at the wheel arches, and the lower skins of the side cargo and rear doors. The doors rust from the inside out -… Repairs typically run $400-$5,000. Severity: medium.
What is the 1996-2014 GMC Savana Intake Manifold Gasket Coolant and Oil Leak on Vortec V8?
Savana V8s develop intake manifold gasket leaks that show up either as an external drip - usually coolant down the driver's side of the block, or oil at the rear of the valley - or, worse, as an internal leak that lets coolant into the oil. Owners of 6.0L vans report antifreeze a… Repairs typically run $1,000-$1,400. Severity: medium.
What is the 1996-2025 GMC Savana Rear Cargo Door and Side Door Hinge Wear?
The rear cargo doors and sliding side door hinges wear out from the weight of the doors and constant commercial use. Doors sag, become difficult to close, and the weatherstripping no longer seals properly. Repairs typically run $100-$400. Severity: low.
