The 2009 GMC Savana with the 6.0L Vortec V8 (LY6) is a workhorse van plagued by a catastrophic piston/ring design flaw causing oil consumption and eventual engine failure, plus transmission cooler failures that can take out the 4L80E transmission if not caught early.
Symptoms: Excessive oil consumption (1 quart per 500-1,000 miles), Blue smoke on startup or acceleration, Fouled spark plugs on cylinders 1 and 7 specifically, Check engine light with P0300-series misfire codes, Metal shavings in oil, low compression on AFM cylinders
Fix: The AFM system deactivates cylinders 1, 4, 6, and 7 under light load. Piston rings collapse and score cylinder walls. Requires complete engine rebuild with AFM-delete kit, or replacement short block. 25-35 labor hours for in-frame rebuild, 40-50 for full removal and rebuild.
Estimated cost: $4,500-8,500
Transmission Oil Cooler Line Failure at Radiator
Common · high severity
Typical onset: 80,000-150,000 mi
Symptoms: Pink or milky transmission fluid (coolant contamination), Transmission slipping or delayed engagement, Engine coolant looks brown or oily, Overheating transmission temperature, Catastrophic transmission failure if driven after mixing
Fix: Steel cooler lines rust through where they connect to radiator, or internal radiator cooler fails. Once coolant mixes with ATF, transmission is toast. Requires radiator replacement, external cooler addition, complete transmission flush (if caught early), or full 4L80E rebuild/replacement. 3-5 hours for cooler/radiator, add 12-18 hours if transmission needs rebuild.
Symptoms: Coolant seeping from front or rear of intake manifold, Rough idle or misfire codes after coolant enters cylinder, External coolant leak pooling on top of engine, Overheating due to coolant loss, White smoke if internal leak is severe
Fix: Composite intake manifold gaskets fail on 6.0L Vortec engines. Requires manifold removal, gasket replacement with updated parts, valley pan inspection. 6-8 labor hours. Often done alongside spark plugs and valve cover gaskets while you're in there.
Estimated cost: $900-1,400
Fuel Pump and Fuel Filter Clogging
Occasional · medium severity
Typical onset: 120,000-180,000 mi
Symptoms: Hard starting, especially after sitting overnight, Loss of power under load or acceleration, Engine stalling at idle or low speed, Fuel pressure dropping below 55 PSI, Check engine light with lean codes (P0171/P0174)
Fix: In-tank fuel pump fails or external inline fuel filter (under driver side frame rail) clogs with debris. Filter should be replaced every 30k but is often neglected. Pump replacement requires dropping 31-gallon tank. 2-3 hours for filter, 4-5 hours for pump.
Symptoms: Clunk when shifting from Park to Drive or Reverse, Vibration through floor at idle in gear, Driveline shudder on acceleration, Visible separation or cracking in rubber mount
Fix: Rubber transmission crossmember mount deteriorates from heat and age. Causes excessive drivetrain movement. Simple replacement with upgraded polyurethane mount recommended. 1-1.5 labor hours.
Estimated cost: $200-350
EVAP Vent Valve Solenoid Failure
Occasional · low severity
Symptoms: Check engine light with P0449 or P0455 codes, Fuel tank difficult to fill (pump keeps clicking off), Fuel smell near rear of vehicle, Failed emissions test
Fix: Vent valve solenoid on top of fuel tank or in frame rail fails, preventing EVAP system from sealing. Requires accessing top of tank or following vent lines. 1.5-2 hours labor.
Estimated cost: $250-450
Owner tips
Disable AFM immediately with a Range/AFM disabler device or custom tune - costs $150-400 but can save the engine
Replace transmission cooler lines and add auxiliary cooler BEFORE they fail (preventive cost $600-800)
Change fuel filter every 30,000 miles religiously - it's cheap insurance
Use 5W-30 synthetic oil and check level every 500 miles once past 80k - oil consumption is your early warning
Inspect transmission fluid color every oil change - pink/milky means stop driving immediately
Buy only if AFM has been deleted and transmission cooler lines have been replaced/upgraded; otherwise budget $5k-8k for inevitable engine work within 50k miles.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
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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.
Consequence: An overheated electrical circuit increases the risk of a fire.
Remedy: Dealers will properly seal the rear HVAC blower motor circuits at the left side B-pillar, free of charge. Owner notification letters were mailed May 2, 2023. Owners may contact Chevrolet customer service at 1-800-222-1020 or GMC customer service at 1-800-462-8782. GMC's number for this recall is N222386050.
EQUIPMENT · 18V267000
2018-04-26
General Motors LLC (GM) is recalling certain 2009-2014 Chevrolet Silverado HD and GMC Sierra HD, 2009 GMC Topkick 5000, 6000, 7000 and 8000 Series and Isuzu F Series, and 2009-2018 Chevrolet Express, and GMC Savana vehicles, equipped with certain Plastic-Handle Fire Extinguishers or Push Button 'Pindicator' Fire Extinguishers. These extinguishers may become clogged, preventing the extinguisher from discharging as expected or requiring excessive force to activate the extinguisher. Additionally, in certain models, the nozzle may detach from the valve assembly with enough force that it could cause injury and also render the product inoperable. For a full list of the affected fire extinguisher models visit: https://static.nhtsa.gov/odi/rcl/2017/RMISC-17E062-5427.pdf
Consequence: In the event of a fire, if the fire extinguisher does not function properly, it can increase the risk of injury.
Remedy: GM will notify owners, instructing them to contact Kidde to get a replacement fire extinguisher, free of charge. The recall began June 11, 2018. Owners may contact Chevrolet customer service at 1-800-222-1020, GMC customer service at 1-800-462-8782, and Isuzu customer service at 1-866-441-9638. GM's number for this recall is 18146.
AIR BAGS:FRONTAL · 14V117000
2014-03-17
General Motors LLC (GM) is recalling certain model year 2009-2014 Chevrolet Express and GMC Savana vans manufactured January 27, 2009, through March 7, 2014 with a gross vehicle weight rating of 10,000 pounds and less and equipped with front passenger air bags. In the affected vehicles, during a frontal impact below the air bag deployment threshold, if an unbelted front passenger's head hits the instrument panel above where the passenger air bag is located, the panel may not sufficiently absorb the impact. As such, these vehicles fail to meet the requirements of Federal Motor Vehicle Safety Standard number 201, "Occupant Protection in Interior Impact."
Consequence: In the event of a crash below the air bag deployment threshold, an unbelted front passenger seat occupant has an increased risk of injury.
Remedy: GM will notify owners, and dealers will modify the passenger instrument panel free of charge. Notices to the owners of the heavy duty vans were mailed on April 28, 2014. The recall began on May 19, 2014. Chevrolet owners may call 1-800-630-2438. GMC owners may call 1-866-996-9463. GM's number for this recall is 14082.
EQUIPMENT ADAPTIVE/MOBILITY · 12V169000
2012-04-17
MAIN MOBILITY IS RECALLING CERTAIN CONVERSION VANS BUILT ON MODEL YEAR 2008-2010 CHEVROLET EXPRESS, 2009 GMC SAVANA, AND 2010 FORD TRANSIT CONNECT CHASSIS, AND FITTED WITH CERTAIN BRAUN WHEELCHAIR LIFTS. OVER TIME AND WITH FREQUENT USE, THE ROLL STOP LATCHES ON THE WHEELCHAIR LIFTS OUTER BARRIER MAY BECOME BENT OR MISALIGNED.
Consequence: A WHEELCHAIR OCCUPANT MAY DEFEAT OR RIDE OVER THE INSUFFICIENTLY LATCHED ROLL STOP. IF THIS OCCURS WHEN THE LIFT PLATFORM IS IN AN ELEVATED POSITION, THE WHEELCHAIRS OCCUPANT COULD FALL AND SUSTAIN INJURY.
Remedy: MAIN MOBILITY IS WORKING WITH BRAUN TO NOTIFY OWNERS, AND BRAUN DEALERS WILL REPAIR THE VEHICLES, FREE OF CHARGE. MAIN MOBILITY HAS NOT PROVIDED A NOTIFICATION SCHEDULE. OWNERS MAY CONTACT MAIN MOBILITY AT 1-716-759-6811.
EQUIPMENT ADAPTIVE/MOBILITY · 10V205000
2010-05-13
MAIN MOBILITY IS RECALLING CERTAIN MODEL YEAR 2008 AND 2009 CONVERSION VANS BUILT ON CHEVROLET EXPRESS AND GMC SAVANA CHASSIS FROM OCTOBER 2007 THROUGH MAY 2010 AND FITTED WITH CERTAIN RICON S SERIES AND K SERIES L-MODEL WHEELCHAIR LIFTS. DUE TO A PROBLEM IN THE SOFTWARE THAT CONTROLS THE LIFT'S "UP" FUNCTION, SHOULD THE "UP" BUTTON BE RELEASED BEFORE THE FLOOR LEVEL LIMIT SWITCH IS ACTIVATED, THE LIFT MAY CONTINUE ITS UPWARD TRAVEL AND MAY OVERRUN THE FLOOR LEVEL CUT OFF POINT.
Consequence: WHEN THE PLATFORM OVERRUNS THE VEHICLE FLOOR LEVEL AND STOPS AT AN ANGLE FROM 15-20 DEGREES, IT IS POSSIBLE FOR A PERSON IN A WHEELCHAIR TO TIP OVER AND FOR SOMEONE STANDING ON THE PLATFORM TO FALL, POSSIBLY RESULTING IN INJURIES.
Remedy: MAIN MOBILITY WILL NOTIFY OWNERS AND THE REPAIRS WILL BE PERFORMED BY AUTHORIZED RICON DEALERS FREE OF CHARGE. A SOFTWARE SOLUTION FOR THIS SAFETY DEFECT IS UNDER INVESTIGATION. UNTIL THE SOFTWARE SOLUTION IS AVAILABLE, RICON WILL PROVIDE OWNERS WITH A BULLETIN OUTLINING PROPER WHEELCHAIR LIFT OPERATION AND WILL SHIP OWNERS A DVD-BASED TRAINING AID TO PROMOTE PROPER LIFT OPERATION AT NO COST. THE SAFETY RECALL BEGAN ON MAY 27, 2010. OWNERS MAY CONTACT RICON AT 1-818-267-3000 OR MAIN MOBILITY AT 1-716-759-6811.
VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM · 10V096000
2010-03-12
GENERAL MOTORS IS RECALLING CERTAIN MODEL YEAR 2009-2010 CHEVROLET EXPRESS AND GMC SAVANA VEHICLES FOR FAILING TO COMPLY WITH FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 103, "WINDSHIELD WIPING AND WASHING SYSTEMS." THESE VEHICLES WERE BUILT WITH HEATING, VENTILATION, AND AIR CONDITIONING (HVAC) CONTROL KNOBS THAT MAY FRACTURE AND SPIN ON THE CONTROL SHAFT. THE DRIVER MAY NO LONGER BE ABLE TO CONTROL THE HEATING, COOLING, AND VENTILATION FOR THE VEHICLE.
Consequence: IF THIS CONDITION AFFECTS THE DEFROST SYSTEM WHEN IT IS REQUIRED, IT MAY DECREASE THE DRIVER'S VISIBILITY, AND COULD POSSIBLY RESULT IN A CRASH.
Remedy: DEALERS WILL REPLACE ALL HVAC CONTROL KNOBS FREE OF CHARGE. THE SAFETY RECALL BEGAN ON MARCH 11, 2010. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438 AND GMC AT 1-866-996-9463 OR AT THE OWNER CENTER AT WWW.GMOWNERCENTER.COM.
EQUIPMENT ADAPTIVE/MOBILITY · 09V270000
2009-07-06 · EQ08011
MAIN MOBILITY IS RECALLING 185 MODEL YEAR 2005 THROUGH 2009 CHEVROLET EXPRESS AND GMC SAVANA VANS MANUFACTURED BETWEEN APRIL 1, 2005 AND JUNE 25, 2009, EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 404, "PLATFORM LIFT INSTALLATIONS IN MOTOR VEHICLES." THE THRESHOLD WARNING SYSTEM MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER IN A CERTAIN SPOT WITHIN THE DEFINED THRESHOLD AREA.
Consequence: THE USER OF THE LIFT COULD BE INJURED SHOULD THE LIFT MOVE UNINTENTIONALLY.
Remedy: MAIN MOBILITY IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PLEASE SEE 07E095). OWNERS MAY CONTACT RICON AT 1-818-267-3000 OR MAIN MOBILITY AT 1-716-759-6811.
EQUIPMENT ADAPTIVE/MOBILITY · 09V272000
2009-07-06 · EQ08011
MAIN MOBILITY IS RECALLING 185 MODEL YEAR 2005 THROUGH 2009 CHEVROLET EXPRESS AND GMC SAVANA VANS MANUFACTURED BETWEEN APRIL 1, 2005 AND JUNE 25, 2009, EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 403, "PLATFORM LIFT INSTALLATIONS IN MOTOR VEHICLES." THE ANTI-STOW INTERLOCK MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER. THE PRESSURE SENSING SWITCH THAT DETECTS THE PRESENCE OF WEIGHT ON THE PLATFORM WAS NOT ADJUSTED TO THE NECESSARY SENSITIVITY LEVEL. THE LIFT COULD STOW EVEN THOUGH SOMEONE OR SOMETHING IS STILL ON THE LIFT.
Consequence: THE USER OF THE LIFT COULD BE INJURED SHOULD THE LIFT MOVE UNINTENTIONALLY.
Remedy: MAIN MOBILITY IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PLEASE SEE 07E097). OWNERS MAY CONTACT RICON AT 1-818-267-3000 OR MAIN MOBILITY AT 1-716-759-6811.
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