Размеры кузова — один из важнейших параметров при выборе машины. Чем больше машина, тем сложнее она в управлении в современном городе, однако и безопасней. Габаритные размеры Шевроле Экспресс определяются по трём величинам: длина кузова, ширина кузова и высота кузова. Как правило длину измеряют от наиболее выдающегося вперёд места переднего бампера до самого удалённого места заднего бампера. Ширину кузова мерят в самом широком месте: как правило это либо колёсные арки, либо центральные стойки кузова. А вот с высотой не всё так просто: её мерят от земли до крыши автомобиля; высота рейлингов в общую высоту кузова не входит.
Габаритные размеры Chevrolet Express от 5537 x 2006 x 2006 до 6200 x 2011 x 2141 мм, а масса от 2105 до 2911 кг.
| Комплектации | Габариты | Масса, кг |
| 2.8 TD AT 3500 Regular Wheelbase | 5692 x 2011 x 2148 | 2340 |
| 2.8 TD AT 2500 Regular Wheelbase | 5692 x 2011 x 2148 | 2340 |
| 4.3 AT 1500 Regular Wheelbase | 5692 x 2011 x 2148 | 2340 |
| 4.3 AT 2500 Regular Wheelbase | 5692 x 2011 x 2148 | 2340 |
| 4.8 AT 2500 Regular Wheelbase | 5692 x 2011 x 2148 | 2340 |
| 4.8 AT 3500 Regular Wheelbase | 5692 x 2011 x 2148 | 2340 |
| 5.3 AT 2500 Regular Wheelbase | 5692 x 2011 x 2148 | 2340 |
| 5.3 AT 3500 Regular Wheelbase | 5692 x 2011 x 2148 | 2340 |
| 5.3 AT 1500 Regular Wheelbase | 5692 x 2011 x 2148 | 2340 |
| 6.0 AT 3500 Regular Wheelbase | 5692 x 2011 x 2148 | 2340 |
| 6.6 TD AT 3500 Regular Wheelbase | 5692 x 2011 x 2148 | 2340 |
| 4.3 AT 3500 Regular Wheelbase | 5692 x 2011 x 2148 | 2358 |
| 5.3 AT AWD 1500 Regular Wheelbase | 5692 x 2011 x 2148 | 2450 |
| 6.0 AT 2500 Regular Wheelbase | 5962 x 2011 x 2148 | 2340 |
| 2.8 TD AT 3500 Extended Wheelbase | 6200 x 2011 x 2141 | 2426 |
| 2.8 TD AT 2500 Extended Wheelbase | 6200 x 2011 x 2141 | 2426 |
| 4.3 AT 2500 Extended Wheelbase | 6200 x 2011 x 2141 | 2426 |
| 4.8 AT 3500 Extended Wheelbase | 6200 x 2011 x 2141 | 2426 |
| 5.3 AT 3500 Extended Wheelbase | 6200 x 2011 x 2141 | 2426 |
| 6.0 AT 3500 Extended Wheelbase | 6200 x 2011 x 2141 | 2426 |
| 6.0 AT 2500 Extended Wheelbase | 6200 x 2011 x 2141 | 2426 |
| 6.6 TD AT 3500 Extended Wheelbase | 6200 x 2011 x 2141 | 2426 |
| 4.3 AT 3500 Extended Wheelbase | 6200 x 2011 x 2141 | 2911 |
| Комплектации | Габариты | Масса, кг |
| 2.8 TD AT 3500 Regular LS/LT | 5692 x 2011 x 2131 | 2760 |
| 2.8 TD AT 2500 Regular LS/LT | 5692 x 2011 x 2131 | 2760 |
| 4.3 AT 2500 Regular LS/LT | 5692 x 2011 x 2131 | 2760 |
| 4.3 AT 3500 Regular LS/LT | 5692 x 2011 x 2131 | 2760 |
| 4.8 AT 2500 Regular LS/LT | 5692 x 2011 x 2131 | 2760 |
| 4.8 AT 3500 Regular LS/LT | 5692 x 2011 x 2131 | 2760 |
| 5.3 AT 2500 Regular LS/LT | 5692 x 2011 x 2131 | 2760 |
| 5.3 AT 3500 Regular LS/LT | 5692 x 2011 x 2131 | 2760 |
| 6.0 AT 3500 Regular LS/LT | 5692 x 2011 x 2131 | 2760 |
| 6.0 AT 2500 Regular LS/LT | 5692 x 2011 x 2131 | 2760 |
| 6.6 TD AT 3500 Regular LS/LT | 5692 x 2011 x 2131 | 2760 |
| 2.8 TD AT 3500 Extended LS/LT | 6200 x 2011 x 2105 | 2911 |
| 4.3 AT 3500 Extended LS/LT | 6200 x 2011 x 2105 | 2911 |
| 4.8 AT 3500 Extended LS/LT | 6200 x 2011 x 2105 | 2911 |
| 5.3 AT 3500 Extended LS/LT | 6200 x 2011 x 2105 | 2911 |
| 6.0 AT 3500 Extended LS/LT | 6200 x 2011 x 2105 | 2911 |
| 6.6 TD AT 3500 Extended LS/LT | 6200 x 2011 x 2105 | 2911 |
| Комплектации | Габариты | Масса, кг |
| 4.3 AT 1500 Regular Wheelbase | 5537 x 2006 x 2006 | 2105 |
| 4.3 AT 2500 Regular Wheelbase | 5537 x 2006 x 2006 | 2105 |
| 5.0 AT 1500 Regular Wheelbase | 5537 x 2006 x 2006 | 2459 |
| 5.0 AT 2500 Regular Wheelbase | 5537 x 2006 x 2006 | 2459 |
| 5.7 AT 1500 Regular Wheelbase | 5537 x 2006 x 2006 | 2459 |
| 5.7 AT 2500 Regular Wheelbase | 5537 x 2006 x 2006 | 2459 |
| 5.7 AT 3500 Regular Wheelbase | 5537 x 2006 x 2006 | 2459 |
| 6.5 AT 2500 Regular Wheelbase | 5537 x 2006 x 2006 | 2459 |
| 6.5 AT 3500 Regular Wheelbase | 5537 x 2006 x 2006 | 2459 |
| 8.1 AT 3500 Regular Wheelbase | 5537 x 2006 x 2006 | 2459 |
| 4.3 AT 2500 Extended Wheelbase | 6066 x 2017 x 2082 | 2814 |
| 5.0 AT 2500 Extended Wheelbase | 6066 x 2017 x 2082 | 2814 |
| 5.7 AT 2500 Extended Wheelbase | 6066 x 2017 x 2082 | 2814 |
| 5.7 AT 3500 Extended Wheelbase | 6066 x 2017 x 2082 | 2814 |
| 6.5 AT 2500 Extended Wheelbase | 6066 x 2017 x 2082 | 2814 |
| 6.5 AT 3500 Extended Wheelbase | 6066 x 2017 x 2082 | 2814 |
| 8.1 AT 3500 Extended Wheelbase | 6066 x 2017 x 2082 | 2814 |
| Комплектации | Габариты | Масса, кг |
| 4.3 AT 1500 Series SWB | 5537 x 2006 x 2006 | 2105 |
| 4.3 AT 2500 Series SWB | 5537 x 2006 x 2006 | 2105 |
| 5.0 AT 1500 Series SWB | 5537 x 2006 x 2006 | 2459 |
| 5.0 AT 2500 Series SWB | 5537 x 2006 x 2006 | 2459 |
| 5.7 AT 1500 Series SWB | 5537 x 2006 x 2006 | 2459 |
| 5.7 AT 2500 Series SWB | 5537 x 2006 x 2006 | 2459 |
| 5.7 AT 3500 Series SWB | 5537 x 2006 x 2006 | 2459 |
| 6.5 AT 2500 Series SWB | 5537 x 2006 x 2006 | 2459 |
| 6.5 AT 3500 Series SWB | 5537 x 2006 x 2006 | 2459 |
| 8.1 AT 3500 Series SWB | 5537 x 2006 x 2006 | 2459 |
| 5.7 AT SLT SWB | 6045 x 2006 x 2108 | 2459 |
| 4.3 AT 2500 Series LWB | 6066 x 2017 x 2082 | 2814 |
| 5.0 AT 2500 Series LWB | 6066 x 2017 x 2082 | 2814 |
| 5.7 AT 2500 Series LWB | 6066 x 2017 x 2082 | 2814 |
| 5.7 AT 3500 Series LWB | 6066 x 2017 x 2082 | 2814 |
| 6.5 AT 2500 Series LWB | 6066 x 2017 x 2082 | 2814 |
| 6.5 AT 3500 Series LWB | 6066 x 2017 x 2082 | 2814 |
| 8.1 AT 3500 Series LWB | 6066 x 2017 x 2082 | 2814 |