Choosing the right cutaway bus chassis can significantly impact performance, reliability, and long-term costs for transit operators, schools, churches, and shuttle services. Two dominant players in this space—Ford and Chevy—offer strong contenders with distinct advantages. But how do you decide which is the better fit for your transportation needs?

Let’s break down the core differences between Ford and Chevy cutaway bus chassis, comparing everything from engine options and maintenance to drivability and value.

Understanding The Cutaway Bus Platform

A cutaway bus is built from a stripped-down van or truck chassis, where the manufacturer leaves the rear section open for custom upfitting. It offers the flexibility to design a passenger bus, shuttle, or service vehicle based on your requirements. Ford and Chevy dominate this segment with their respective E-Series and Express chassis.

Engine Options And Performance

Ford E-Series Cutaway

The Ford E-350 and E-450 are the go-to choices for medium-duty cutaway buses. Ford’s 7.3L V8 gas engine, known as the “Godzilla” engine, delivers exceptional torque and power. It offers up to 468 lb-ft of torque, making it ideal for heavier payloads and hilly routes.

Chevy Express Cutaway

Chevy’s Express 3500 and 4500 models come with a 6.6L V8 engine that produces up to 464 lb-ft of torque. It’s a solid and reliable option with a strong focus on efficiency. The Express cutaway is also available in diesel options (in select older models), which some fleet managers prefer for fuel economy over long distances.

Verdict: Ford edges out slightly in horsepower, while Chevy competes closely on torque and offers a smoother throttle response for urban driving.

Transmission And Drivability

Ford’s TorqShift® 6-speed automatic transmission is engineered to handle higher towing and hauling demands. It offers integrated tow/haul modes, ideal for larger cutaway bus builds.

Chevy uses a 6-speed heavy-duty automatic transmission, which is equally capable but slightly more responsive in stop-and-go city driving. Drivers often report that Chevy’s handling feels more “van-like,” while Ford leans toward a truck-style experience.

Verdict: Ford suits heavy-duty, long-distance routes. Chevy is easier to maneuver in urban shuttle routes.

Payload And Towing Capacity

The Ford E-450 can handle a GVWR (Gross Vehicle Weight Rating) of up to 14,500 lbs, while the Chevy Express 4500 supports up to 14,200 lbs. Both offer impressive payload capacity, but Ford’s slightly higher GVWR gives it a bit more flexibility for larger or heavier configurations.

Verdict: Ford offers marginally higher capacity—ideal for ADA-compliant cutaway buses with wheelchair lifts or added cargo.

Fuel Efficiency

Fuel economy in cutaway buses isn’t typically the primary selling point, but it does factor into fleet operation costs. The Ford 7.3L V8 has decent mileage for its size, averaging 10–12 MPG under load. Chevy’s 6.6L V8 tends to perform similarly, though some users report better economy in lighter builds.

Verdict: It’s nearly a tie, but Chevy may offer a slight edge in mileage depending on configuration.

Serviceability And Maintenance

Ford’s E-Series chassis has remained consistent for decades, making parts easy to find and repairs familiar to most mechanics. Fleet operators appreciate the simplicity and long-standing support Ford offers.

Chevy also has a broad service network and solid reliability, but some parts—especially diesel-related components—may be more expensive or less available in certain regions.

Verdict: Ford wins for widespread parts availability and lower long-term service costs.

Interior Comfort And Upfitting Flexibility

Both brands offer strong platforms for custom interiors, but Ford is often favored by upfitters due to the flat floor design and electrical integration. Chevy’s chassis may require additional modifications for complex configurations.

Verdict: Ford leads in ease of upfitting and interior buildout flexibility for larger or custom cutaway bus designs.

Price And Resale Value

Chevy cutaway buses generally come with a slightly lower sticker price, appealing to budget-conscious buyers. However, Ford’s E-Series maintains higher resale value over time due to brand reputation and long-term durability.

Verdict: Chevy offers better upfront value; Ford offers stronger returns on resale.

Conclusion: Which Chassis Should You Choose?

When choosing between a Ford or Chevy cutaway bus, your decision should depend on your operational priorities. If you need a powerhouse for long routes, heavy-duty lifting, or extensive customization, the Ford E-Series chassis is likely the better option. On the other hand, if you're looking for a cost-effective, nimble, and fuel-conscious shuttle bus, Chevy’s Express cutaway might be your best bet.

Both options are reliable, but they cater to slightly different use cases. Evaluate your route demands, passenger load, upfitting needs, and long-term service preferences to find the right fit.

Need help deciding which chassis works best for your next cutaway bus project? Connect with vehicle upfitters or commercial transportation specialists who can guide you based on your unique needs.