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2005 Chevrolet Express 3500

Owner reports · Recalls · Investigations

Limited comparison data

There is not enough comparable history to draw a useful model-year comparison.

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How this year compares

Owner complaints by model year

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Counts vary with age, sales and reporting. They are not failure rates.

What owners reported most

All reported categories

Tap a category to read its complaints. One report may name several components.

When problems were reported

Mileage at the reported incident

Limited mileage data: 13 of 17 reports include usable mileage. There isn’t enough coverage to show a useful chart.

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Structure. Review the 4 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Tires. Review the 4 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Seat Belts. Review the 3 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

1 crash reports2 fire reports1 injury reports

What owners actually said

17 reports
170,000 miles · Aug 23, 2018
Electrical SystemFuel/propulsion SystemUnknown Or OtherFire

WHEN I NORMAL DRIVE UNDER HOOD FIRE THE VEHICLE BURN OUT IF YOU NEED MORE FILE OR PICTURE I CAN SEND MAIL MY E MAIL ADDRESS (XXXX) PARTS OF THIS DOCUMENT HAVE BEEN REDACTED TO PROTECT PERSONALLY IDENTIFIABLE INFORMATION PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

NHTSA ODI #11121976

150,000 miles · Aug 23, 2018
Tires

BF GOODRICH TIRE DOT BE11 JD11 4012 LT 24.5/75 R16 120/1160 TIRE IS BULGING AT CENTER OF TREED, CAUSING VEHICLE TO JUMP AND BOUNCE, CAUSING SPRING DAMAGE AND SEVERE VIBRATION OF VEHICLE AT HIGH SPEED..TIRE LOOKS AS IF IS GOING TO BLOW OUT..

NHTSA ODI #11121842

77,000 miles · Jul 9, 2015
Tires

TL* THE CONTACT OWNS A 2005 CHEVROLET EXPRESS 3500 EQUIPPED WITH KENDA KLEVER TIRES, SIZE: LT225/75 R16. WHILE DRIVING AT APPROXIMATELY 65 MPH, THE REAR PASSENGER SIDE TIRE BLEW OUT. THE TIRE WAS REPLACED WITH A SPARE. THE CONTACT WAS A MECHANIC WHO DIAGNOSED THAT THE TREAD SEPARATED. THE TIRE WAS NOT REPLACED. THE MANUFACTURER …

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TL* THE CONTACT OWNS A 2005 CHEVROLET EXPRESS 3500 EQUIPPED WITH KENDA KLEVER TIRES, SIZE: LT225/75 R16. WHILE DRIVING AT APPROXIMATELY 65 MPH, THE REAR PASSENGER SIDE TIRE BLEW OUT. THE TIRE WAS REPLACED WITH A SPARE. THE CONTACT WAS A MECHANIC WHO DIAGNOSED THAT THE TREAD SEPARATED. THE TIRE WAS NOT REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE TIRE FAILURE MILEAGE WAS 6,000 AND THE VEHICLE FAILURE MILEAGE WAS 77,000. MA 10/5

NHTSA ODI #10732931

75,000 miles · Jul 24, 2013
Structure

PAINT PEEL ON ROOF, HOOD, DOORS. *TR

NHTSA ODI #10531569

76,000 miles · May 25, 2012
Service BrakesTiresWheels

2005 CHEVROLET EXPRESS 3500. PARKING BRAKE CABLE ON REAR, DRIVERS SIDE, RUBBING AGAINST SIDE OF TIRE. TIRE RUBS DOWN UNTIL IT BREAKS. TIRE WAS TOTALLY SHREDDED BUT I WAS ABLE TO SLOW AND STEER TO SIDE OF ROAD. NEW TIRE PUT ON BUT THEY DID NOT SEE THE CABLE IN THE WAY OR RUBBING! I ONLY SAW IT BECAUSE I WAS LOOKING UNDER THE CAR …

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2005 CHEVROLET EXPRESS 3500. PARKING BRAKE CABLE ON REAR, DRIVERS SIDE, RUBBING AGAINST SIDE OF TIRE. TIRE RUBS DOWN UNTIL IT BREAKS. TIRE WAS TOTALLY SHREDDED BUT I WAS ABLE TO SLOW AND STEER TO SIDE OF ROAD. NEW TIRE PUT ON BUT THEY DID NOT SEE THE CABLE IN THE WAY OR RUBBING! I ONLY SAW IT BECAUSE I WAS LOOKING UNDER THE CAR FOR A NEW METALLIC CLANKING NOISE (THAT IS SOMETHING ELSE). MY NEW TIRE WAS ALMOST RUBBED THROUGH AFTER ONLY 3 WEEKS. I PULLED THE CABLE WAY BACK INTO ITS RETAINER BUT THE RETAINER IS ABOUT 1.5 SQUARE INCHES AND THE CABLE IS ONLY 1/8 IN SO IS NOT FIRMLY HELD IN PLACE (ONLY BY SOME FRICTION). IF YOU HAVE A CHEVY EXPRESS, CHECK YOUR CABLE AND TIRE. *TR

NHTSA ODI #10459650

78,000 miles · May 14, 2012
Seat BeltsInjury

OUR SEAT BELTS WHEN HITTING MY BREAKS JUST UNLATCHED AND FELL APART ON THE DRIVER & PASSENGER SIDE. *JS

NHTSA ODI #10458279

184,000 miles · Aug 18, 2011
Structure

TL* THE CONTACT OWNS A 2005 CHEVROLET EXPRESS 3500. THE CONTACT STATED THAT THE SIDE DOOR HINGES WERE COLLECTING MOISTURE AND CAUSING THEM TO RUST, MAKING THE DOOR INOPERABLE. THE CONTACT CALLED THE MANUFACTURER REGARDING THE FAILURE AND THE MANUFACTURER ADVISED THAT THERE WERE NO RECALLS REGARDING THE DOOR HINGES. THE CONTAC…

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TL* THE CONTACT OWNS A 2005 CHEVROLET EXPRESS 3500. THE CONTACT STATED THAT THE SIDE DOOR HINGES WERE COLLECTING MOISTURE AND CAUSING THEM TO RUST, MAKING THE DOOR INOPERABLE. THE CONTACT CALLED THE MANUFACTURER REGARDING THE FAILURE AND THE MANUFACTURER ADVISED THAT THERE WERE NO RECALLS REGARDING THE DOOR HINGES. THE CONTACT STATED THE REAR SIDE DOOR DOES NOT OPEN AND COULD CAUSE A MAJOR SAFETY ISSUE. THE FAILURE MILEAGE AS 184,000.

NHTSA ODI #10420011

Mileage unknown · Jul 1, 2010
Unknown Or OtherFire

2005 CHEVY EXPRESS VAN CAUGHT FIRE IN THE ENGINE COMPARTMENT, COMPLETE BURN. *TR

NHTSA ODI #10341054

9,800 miles · Jun 21, 2010
Service Brakes, Hydraulic

THIS IS A 29' MOTORHOME, WHEN TOWING IN HILLS/MOUNTAINS. GOING DOWN HILL ATTEMPTING TO SLOW DOWN THE VEHICLE, THE MOTORHOME STARTS SHAKING THROUGHOUT AND THE BRAKES BECOME ALMOST INEFFECTIVE. THE DEALERSHIP SERVICE DEPT INFORMED ME THE BRAKES ARE BARELY ADEQUATE TO STOP THE MOTORHOME WITHOUT A TRAILER. THE CHEVORLET G3500 HAS A…

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THIS IS A 29' MOTORHOME, WHEN TOWING IN HILLS/MOUNTAINS. GOING DOWN HILL ATTEMPTING TO SLOW DOWN THE VEHICLE, THE MOTORHOME STARTS SHAKING THROUGHOUT AND THE BRAKES BECOME ALMOST INEFFECTIVE. THE DEALERSHIP SERVICE DEPT INFORMED ME THE BRAKES ARE BARELY ADEQUATE TO STOP THE MOTORHOME WITHOUT A TRAILER. THE CHEVORLET G3500 HAS A TOWING RATINGS PER THE CHARTS OF 10000#. I WAS TOWING LESS THAN 5000#. *TR

NHTSA ODI #10339341

69,000 miles · Apr 1, 2010
Service Brakes, Hydraulic

OUR 2005 CHEVY EXPRESS 1 TON PASSENGER VAN BRAKES BY ITS SELF. IT HAS BEEN HAPPENING SINCE JULY 2009. WE TOOK IT TO A LOCAL MECHANIC AND HE REPLACED YAW SENSOR IT DID NOT STOP THE BRAKING. WE TOOK IT TO WHITE'S CHEVROLET DEALERSHIP IN CASPER WY AND THEY REPLACED F- MODULE IT DID NOTHING TO CHANGE THE PROBLEM. THE RIGHT FRONT…

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OUR 2005 CHEVY EXPRESS 1 TON PASSENGER VAN BRAKES BY ITS SELF. IT HAS BEEN HAPPENING SINCE JULY 2009. WE TOOK IT TO A LOCAL MECHANIC AND HE REPLACED YAW SENSOR IT DID NOT STOP THE BRAKING. WE TOOK IT TO WHITE'S CHEVROLET DEALERSHIP IN CASPER WY AND THEY REPLACED F- MODULE IT DID NOTHING TO CHANGE THE PROBLEM. THE RIGHT FRONT BRAKE WOULD BRAKE AND THE THE TRACTION SYSTEM WILL KICK IN. WE TOOK IT BACK TO THE CHEVY DEALER AND THEY SAID THEY WOULD FIX IT. THE PERSON WE WERE DEALING WITH, BRIAN PARKS, CALLED AT ONE POINT AND SAID WE HAD A GHOST IN THE VAN. THEY HAD THE VAN FOR A LITTLE OVER A MONTH AND SAID THE TIRES WERE SLIGHTLY UNEVEN AND THAT MIGHT BE WHAT WAS CAUSING THE BRAKES TO ENGAGE BY THEMSELVES. THEY TOLD US THEY WOULD NO LONGER WORK ON IT AND TO COME AND GET IT. WE PICKED IT UP AND NOW THE LEFT FRONT BRAKE ENGAGES BY ITSELF SO HARD AT TIMES IT PULLS THE VAN TO THE LEFT. WE DON'T KNOW WHAT TO DO TO GET THIS PROBLEM SOLVED. THE VAN IS NOT SAFE ON ICEY ROADS OR DRY FOR THAT MATTER. WHEN THE BRAKE STARTS ENGAGING THE TRACTION CONTROL COMES ON AND THE BRAKE WILL NO LONGER ENGAGE.

NHTSA ODI #10323318

Official recalls

0

No recalls in this snapshot.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

0

No exact-year investigations in this snapshot.