GM Recalls Chevrolet Express and GMC Savana Over Faulty Door Welds

General Motors has issued a recall for 82 vehicles in the U.S. due to a safety defect in certain 2025 Chevrolet Express and GMC Savana models. The recall stems from improperly welded impact beams in the driver’s side door, which could fail to perform as intended in a side-impact crash, increasing the risk of injury. The issue affects 74 Chevrolet Express vans and 8 GMC Savana vehicles manufactured between December 6 and December 10, 2024.

The defect was discovered on December 12, 2024, when a GM employee identified cold welds on a driver’s side door impact beam during a quality inspection at the company’s Wentzville assembly plant. Following an internal investigation, GM determined that a welding robot malfunctioned due to an internal electrical failure, leading to improper welds at the front connection point of the impact beam to the door assembly. As a result, GM’s Safety Field Action Decision Authority (SFADA) decided on February 6, 2025, to initiate a safety recall.

To address the issue, GM dealers will replace the affected driver’s side doors. Since vehicle owners would not have been aware of the defect before the recall, the company does not plan to offer reimbursement. The malfunctioning welding robot was replaced on December 11, 2024, ensuring that vehicles produced afterward have properly welded impact beams.

Dealer notifications about the recall began on February 13, 2025, and GM plans to notify affected owners starting March 6, 2025. Owners with questions about the recall can contact GM for further assistance.

Article by multiple RFHC contributors.

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