Chevy Express 4500 Transmission Problems & Cost

Primarily designed for use with utility and rescue bodies, the Chevrolet Express G4500 is one of the best selling commercial cutaway vans on the market. Durability and serviceability are hallmarks of this heavy hauler. However Chevy Express 4500 transmission problems do happen. So let’s find out what you can do about them.

Need a replacement transmission? Get an estimate for replacement transmissions and local installation. Look up your transmission model by vehicle make and model.

What Transmission Do I Have?

Chevy Express 4500 Transmission Models

Chevy Express 4500 Van: 4L80E Transmission
Chevy Express 4500 Van: 6L90 Transmission

Chevy Express 4500 Transmission Replacement Cost Estimate

Pricing varies by model. To be 100% sure on pricing, have your VIN# handy and use our Get An Estimate feature to look up your transmission by VIN#.

Replacement 6L90 Transmission:

What are the DTC codes related to Chevy Express 4500 transmission problems?

Chevy Express 4500 Technical Service Bulletins (TSB)

TSB 08-07-30-001 – Chevrolet Express 4500 4L80E
Problem – Harsh or delayed shifts, slipping, no forward/reverse gears. Possible DTCs: P0741, P0742, P0751, P0752, P0756, P0757, P0894.
Solution – Rebuild or replace the valve body.

TSB 08-07-30-015 – Chevrolet Express 4500 4L80E
Problem – Harsh shifts, delayed 2-3 shifts, 2-3 shift flare, no 3rd gear, slips in 3rd gear or reverse. Possible DTC 0757.
Solution – If none of the issues described in Bulletin 08-07-30-001 are present (debris in #11 checkball, leak in oil circuit, damage to the direct clutch), then replace the 2-3 shift solenoid due to a possible sticking pintle.

TSB PI488C – No forward or reverse and/or slipping – 6L80 Transmission | 6L90 Transmission
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Problem – Trucks equipped with the 6-speed 6L80 or 6L90 transmission may experience no forward or reverse engagement, or slipping between the gears.

Solution – This problem could be caused by a cracked or split transmission filter. If this is the case, the transmission pump should be disassembled and inspected for possible damage. Inspect for any of the following conditions: – scored pump rotor or pump vanes – scored pump cover or pump rotor pocket – cracked pump slide.

The transmission should also be evaluated for any possible distress to the clutches. GM’s testing and analysis found that split or damaged filters may be caused by a damaged transmission pump. This can send a high pressure fluid spike down the filter neck on a cold start, resulting in the filter body cracking or the filter seam splitting. The filter is not defective and this is not a filter quality issue. Important: Do not replace the filter without inspecting the pump. Failure to inspect the pump and clutches could lead to a repeat of this condition.

Chevy Express 4500 Recalls

None Found

Common Problems with the Chevy Express 4500 Transmission

Solenoid DTC’s – Chevrolet Express 4500 6L90
Problem – A number of diagnostic trouble codes, including P0776, P0796, P2714 and P2723, can be caused by a pressure leak at the end of the clutch regulating valve.
Solution – The bore plug will have to be replaced with updated versions, or modified to accept an O-ring kit.

Lack of Response
Leaking Fluid
Low Fluid
Burning Smell
Grinding or Shaking
Whining, Clunking or Humming
Refuses to Go Into Gear
Torque Converter Issues
Valve Body Issues
Transmission Noisy in Neutral
Gears Slipping
No 3rd or 4th Gear
No 1st or 2nd Gear
No Reverse
Dragging Clutch
Trouble Codes / Check Engine Light

Can I drive with a transmission problem?

Not all Chevy express 4500 transmission problems will keep you from driving it. However as you drive, more stress will be placed on the other components. And it should go without saying, that’s not good for the transmission. So do yourself and your budget a favor, and have your 6L90 transmission problems or 4L80E transmission problems diagnosed and repaired immediately.

How often does a Chevy Express 4500 transmission need to be replaced?

With proper maintenance, this is the following average lifespan of a Chevrolet express 4500 transmission:
4L80E – 120,000-180,000 miles
6L90 – 130,000-200,000 miles

Maintenance and driving style are the two biggest factors in keeping a Chevy Express 4500 6L90 transmission on the road. However design flaws also play a part, and can sometimes sideline a gearbox early in its service life. Rebuilt and used transmissions often have same life expectancy as an OE unit. Remanufactured transmissions on the other hand, can sometimes last a lot longer, providing that modifications have been made to correct the OE design flaws.

How are Chevy Express 4500 transmission issues diagnosed?

Most Chevrolet Express 4500 transmission problems can be narrowed down by simply pulling the diagnostic trouble codes from the OBDII system. Then it’s a matter of visually inspecting the transmission to verify the problem. But sometimes the source of the problems aren’t as obvious, so partial disassembly may be required.

How is a Chevy Express 4500 transmission replaced?

Thanks to its relatively simple body-on-frame design, replacing a Chevrolet Express 4500 6L90 can be accomplished by disconnecting the old transmission from the engine, driveshaft and frame. Once the old gearbox is a lowered out of the way, the new one can be installed in the reverse order. However, the ECU/TCM will have to be reprogrammed in order to accept the new transmission.

Recommendations for Chevy Express 4500 transmission issues?

To save time and get back on the road faster, have your 17-digit truck VIN# handy and you can get an online quote for a reman Chevy Express 4500 transmission here, then find a local shop using our Find a Shop guide to install it for you.

How to Solve Chevy Express 4500 Transmission Problems

Solution A: Buy a Used Chevy Express 4500 Transmission

One of the fastest and most affordable solutions to all your Chevy Express G4500 transmission problems used to buy a used 4L80E / used 6L90 from a local junkyard. However you don’t know how well that transmission was maintained, which means it could develop similar problems, or worse.

Solution B: Buy a Rebuilt Chevy Express 4500 Transmission

The next best option would be getting a rebuilt 4L80E / rebuilt 6L90 from a mechanic or transmission repair center. However if they use an OE master rebuild kit, most of the problems that result from factory design flaws will eventually return. And, the warranty they give you may only be honored at the shop that built the transmission.

Solution C: Buy a Remanufactured Chevy Express 4500 Transmission

One of the best solutions to most Chevrolet Express G4500 transmission problems, is to get a remanufactured 4L80E / remanufactured 6L90 transmission. These are typically built in a factory, and come the closest to “brand new” that you are going to get. As a result, most of these will last longer and save you a bunch of money by reducing downtime.

Need a replacement transmission? Get an estimate for replacement transmissions and local installation. Look up your transmission model by vehicle make and model.

What Transmission Do I Have?

What Problem Does Your Chevy Express 4500 Have?

Let us know the year, mileage and problem you’re having as well as any trouble (OBD) codes you’ve found. If you’ve been given a quote or paid for a repair, we’d like to hear about that too!