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Chevrolet Express
Platform: GMT Van

Starting Issue 2004 3500 Express

Old Sep 23, 2025 | 6:57 PM
  #1  
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Default Starting Issue 2004 3500 Express

Hello.
From the start, A few months ago I started having starting issues. Like it went from starting first try to randomly taking a few tries. Yesterday I was driving and as soon as I turned the van died. It restarted and everything seemed ok. Leaving work I made it down the street as soon I turned it happened again. This time it refused to start. No Noise from fuel pump. This morning I went under van and checked grounds. The ground that went to filler neck was broken. I tried to start van, no go. Repaired ground thinking eh no way it's the issue with no starting. Turned key, Hear pump. Starts right up. So I went to do some things and made it about 30 mins worth of driving. Going straight it dies and will not start again. This van doesn't have an external filter. The only engine light I have had was knock sensor low voltage. I changed the knock sensors and wires (this was a few months ago). Another thing that has started happing a couple weeks ago, randomly my cluster will go bonkers for a few seconds. No idea if it's related but throwing it in there. So when I turn it over it just blubs like it's idling at 200rpm. Lasts a few seconds and stalls, or if you touch the throttle it dies instantly. The tank is full. This actually started the day after I filled it. So just trying to figure out if this is in fact the fuel pump or is there anything else I should be looking at as pulling a full tank is going to suck.
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Old Sep 24, 2025 | 12:11 AM
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All right so I went back out tonight and tried starting. Turn key. "Extra" lights on dash, one being low power mode. No start. Shut off turn key again no "extra" lights on van starts. Took apart dash, pulled dog house, no bad grounds or wires found. After everything was torn apart. Van started. Didn't have cluster plugged in so I don't know what it light up that time.
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Old Sep 24, 2025 | 4:58 PM
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Ok so. Fuel pump is good. Power to fuel pump is either 12v or 1.6v when it won't run. Fuse is good, Relay is good, power to both is good. I have checked every ground I could find. Wiring. Nothing is broken or corroded. What am I missing ? I have had the Security light flash on through out this randomly, could it be related to that ? My husband is laid up heavily sedated after an emergency surgery in the hospital. (Mechanic) My Father and Grandfathers have passed away. (Mechanics) I am literally just running off the things I have learned watching and helping and a bit of google. Any advice would be super helpful. This is one of our work vehicles.
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Old Sep 24, 2025 | 8:31 PM
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I believe the security cuts power to the fuel pump so that is something to look further into
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Old Sep 28, 2025 | 9:28 AM
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Sorry to hear you are having problems, especially under those circumstances.

I agree it is probably a malfunctioning security system cutting power to the fuel pump.

Do you always use the same key? These are chip keys so maybe the chip is damaged or possibly the chip sensor in the column is going bad.

Often times it’s the stupid little stuff that prevents a vehicle from running. On one of my vehicles, I thought I had a fuel pump voltage problem and it turned out to be a bad battery, with 12.97v and 0.25amps (you read that right). I didn’t even know that combination was possible!

Best of luck tracking this down.
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