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2005 Chevrolet Express

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: 16 of 23 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 5 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 4 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes. Review the 4 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

0 crash reports1 fire reports1 injury reports

What owners actually said

23 reports
92,000 miles · Oct 26, 2014
Structure

PAINT PEELING ON ROOF GUTTER AND DOOR AROUND WINDOWS. *TR

NHTSA ODI #10650140

101,000 miles · Jun 30, 2014
Electrical System

KEY GETS STUCK! CAR WONT TURN OVER!,KEY FALLS OUT WHILE DRIVING! EVEN THOUGH ITS A RECALL DEALER WONT FIX. *TR

NHTSA ODI #10607157

82,868 miles · Jun 23, 2014
Fuel System, Gasoline

SERVICED VEHICLE DUE TO *CHECK ENGINE LIGHT. RAN ROUGH, SKIPPED MISFIRING. ACCORDING TO THE REPAIR BILL WE RECEIVED FROM EMERSON AUTO DEALERS. IT APPEARS THAT THE FUEL SYSTEM HAD CORROSION THROUGHOUT THE FUEL SYSTEM AND A HOLE ON THE TOP OF THE FUEL TANK! ALL OF THE FUEL LINES AND INJECTORS AND TANK HAD TO BE REPLACED. THIS IS A…

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SERVICED VEHICLE DUE TO *CHECK ENGINE LIGHT. RAN ROUGH, SKIPPED MISFIRING. ACCORDING TO THE REPAIR BILL WE RECEIVED FROM EMERSON AUTO DEALERS. IT APPEARS THAT THE FUEL SYSTEM HAD CORROSION THROUGHOUT THE FUEL SYSTEM AND A HOLE ON THE TOP OF THE FUEL TANK! ALL OF THE FUEL LINES AND INJECTORS AND TANK HAD TO BE REPLACED. THIS IS A VERY HIGH RISK OF FIRE HAZARD. CONTACTED OUR DEALERSHIP AND WAS INFORMED THAT OUR VIN # HAD NO RECALLS REGARDING ISSUES, ONLY SOME HAD MET THE CRITERIA FOR THAT YEAR?! THIS IS OUTRAGEOUS. WHAT CAN BE DO TO HELP WITH THE COST OF THESE REPAIRS? THANK YOU *TR

NHTSA ODI #10605303

155,000 miles · Oct 23, 2013
Seat Belts

TL* THE CONTACT OWNS A 2005 CHEVROLET EXPRESS. THE CONTACT STATED THAT THE FRONT SEAT BELT BUCKLES WERE JAMMED. THE BUCKLES HAD TO BE BROKEN IN ORDER TO RELEASE THE SEAT BELT. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED. THE FAILURE MILEAGE WAS 155,000.

NHTSA ODI #10549184

130,000 miles · Jul 10, 2012
Electrical SystemFuel/propulsion System

TL* THE CONTACT OWNS A 2005 CHEVROLET EXPRESS CARGO VAN. THE CONTACT WAS TRAVELING 50 TO 55 MPH WHEN THE ENGINE STALLED. THE SECURITY WARNING LIGHT ILLUMINATED WHEN THE FAILURE OCCURRED. INTERMITTENTLY THE VEHICLE ALSO FAILED TO START. THE CONTACT STATED THE FAILURES WERE CAUSED BY THE ANTI THEFT SYSTEM. THE VEHICLE WAS TAKEN …

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TL* THE CONTACT OWNS A 2005 CHEVROLET EXPRESS CARGO VAN. THE CONTACT WAS TRAVELING 50 TO 55 MPH WHEN THE ENGINE STALLED. THE SECURITY WARNING LIGHT ILLUMINATED WHEN THE FAILURE OCCURRED. INTERMITTENTLY THE VEHICLE ALSO FAILED TO START. THE CONTACT STATED THE FAILURES WERE CAUSED BY THE ANTI THEFT SYSTEM. THE VEHICLE WAS TAKEN TO A PRIVATE MECHANIC WHO CONFIRMED THE FUEL PUMP NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED AND THE VIN WAS UNKNOWN. THE FAILURE AND CURRENT MILEAGE WAS 130,000.

NHTSA ODI #10465046

89,000 miles · Jun 7, 2012
Structure

PAINT IS SIMPLY PEELING FLAKING AWAY BY HAND AND I ONLY WASH IT BY HAND ITS TERRIBLE AND 80% OF THE VANS I SEE IN FLORIDA ARE THE SAME.HOW COME NOTHING GETS DONE CHEVY SHOULD PAINT THESE TRUCKS FOR FREE AND HONOR THE BRAND I GUESS I WILL SELL LOOSE LOTS OF MONEY AND BUY A MORE RELIABLE FORD. *JS

NHTSA ODI #10460964

70,000 miles · Jan 18, 2012
Electrical SystemFire

TL* THE CONTACT OWNS A 2005 CHEVROLET EXPRESS G2500. THE CONTACT STATED THAT THE VEHICLE CAUGHT ON FIRE WHILE PARKED. THE FIRE ORIGINATED IN THE INTERIOR WIRES WITHIN THE DASHBOARD OR INSTRUMENTAL PANEL AREA. THE FLAMES SPREAD TO THE DRIVER SEAT, PASSENGER FRONT SEAT AND THE STEERING WHEEL. THE VEHICLE WAS TOWED TO THE DEALER F…

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TL* THE CONTACT OWNS A 2005 CHEVROLET EXPRESS G2500. THE CONTACT STATED THAT THE VEHICLE CAUGHT ON FIRE WHILE PARKED. THE FIRE ORIGINATED IN THE INTERIOR WIRES WITHIN THE DASHBOARD OR INSTRUMENTAL PANEL AREA. THE FLAMES SPREAD TO THE DRIVER SEAT, PASSENGER FRONT SEAT AND THE STEERING WHEEL. THE VEHICLE WAS TOWED TO THE DEALER FOR FURTHER INVESTIGATION. THE FAILURE AND THE CURRENT MILEAGE WAS 70,000.

NHTSA ODI #10444339

58,000 miles · Apr 28, 2009
Service Brakes, Hydraulic

TL*THE CONTACT OWNS A 2005 CHEVROLET EXPRESS CUT-AWAY G3500. WHEN THE CONTACT DEPRESSED THE BRAKE PEDAL AT 10 MPH, THE VEHICLE BECAME DIFFICULT TO STOP. UPON FURTHER INSPECTION, HE NOTICED BRAKE FLUID LEAKING FROM THE HOSES. HE TOOK THE VEHICLE TO A LOCAL REPAIR SHOP AND THE MECHANIC STATED THAT THE BRAKE LINES WERE RUBBING T…

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TL*THE CONTACT OWNS A 2005 CHEVROLET EXPRESS CUT-AWAY G3500. WHEN THE CONTACT DEPRESSED THE BRAKE PEDAL AT 10 MPH, THE VEHICLE BECAME DIFFICULT TO STOP. UPON FURTHER INSPECTION, HE NOTICED BRAKE FLUID LEAKING FROM THE HOSES. HE TOOK THE VEHICLE TO A LOCAL REPAIR SHOP AND THE MECHANIC STATED THAT THE BRAKE LINES WERE RUBBING TOGETHER, WHICH CAUSED THE HOSE TO RUPTURE. THE CONTACT IS IN THE PROCESS OF HAVING THE VEHICLE REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 58,000.

NHTSA ODI #10267068

2,700 miles · Dec 20, 2007
Service Brakes, HydraulicSteeringStructure

2005 CHEVROLET EXPRESS SHOCK TOWER FAILURE. CONSUMER STATED THAT THE SHOCK TOWER CRACKED IN HALF. WAS REPAIRED. SHE STATES THAT THE VEHICLE DEVELOPED A SHIMMY AFTER THE REPAIR. *KB WHEN THE CONSUMER TOOK THE VEHICLE TO THE SHOP FOR THE SHIMMY, SHE WAS INFORMED THE TIE RODS HAD WORN OUT AND THE TECHNICIAN STATED THAT EXCESSIVE …

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2005 CHEVROLET EXPRESS SHOCK TOWER FAILURE. CONSUMER STATED THAT THE SHOCK TOWER CRACKED IN HALF. WAS REPAIRED. SHE STATES THAT THE VEHICLE DEVELOPED A SHIMMY AFTER THE REPAIR. *KB WHEN THE CONSUMER TOOK THE VEHICLE TO THE SHOP FOR THE SHIMMY, SHE WAS INFORMED THE TIE RODS HAD WORN OUT AND THE TECHNICIAN STATED THAT EXCESSIVE WEIGHT AND THE WRONG WHEEL/TIRE SIZE CAUSED ADDITIONAL STRESS AND WEAR AND TEAR ON THE VEHICLE. THE ABS LIGHT FLICKERED.

NHTSA ODI #10212794

27,000 miles · Jul 28, 2007
SuspensionWheels

SUBJECT VEHICLE IS A 2005 CHEVY EXPRESS/EXPLORER CONVERSION VAN. THE PASSENGER SIDE SHOCK TOWER STEEL ARM COMPLETELY SEPARATED AT THE WELDED POINT. I DROVE VEHICLE TO CLOSEST DEALER. WAS TOLD THAT THE VEHICLE TOOK A HIT AND THAT IT WAS NOT COVERED BY MANUFACTURER'S WARRANTY, AND THAT IT WAS NOT SAFE TO DRIVE. WAS TOLD THAT AU…

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SUBJECT VEHICLE IS A 2005 CHEVY EXPRESS/EXPLORER CONVERSION VAN. THE PASSENGER SIDE SHOCK TOWER STEEL ARM COMPLETELY SEPARATED AT THE WELDED POINT. I DROVE VEHICLE TO CLOSEST DEALER. WAS TOLD THAT THE VEHICLE TOOK A HIT AND THAT IT WAS NOT COVERED BY MANUFACTURER'S WARRANTY, AND THAT IT WAS NOT SAFE TO DRIVE. WAS TOLD THAT AUTO INSURANCE MIGHT COVER THE DAMAGE. AT NO TIME WAS THAT VEHICLE INVOLVED IN AN ACCIDENT. FILED CLAIM WITH ALLSTATE. DEALER REPAIR SHOP WAS AUTHORIZED BY IN-HOUSE ADJUSTER TO DETERMINE IF DAMAGE WAS COVERED. INSURANCE ADJUSTER CALLED TO SAY THEY WOULD COVER THE CLAIM. WE DISPUTED THE CLAIM AND ASKED THE ADJUSTER TO VISUALLY INSPECT THE VEHICLE HIMSELF BECAUSE WE FELT IT WAS A MANUFACTURER'S DEFECT. ADJUSTER CONCURRED AND DENIED THE CLAIM. [WE WERE DISTURBED BY THE WAY OUR CLAIM WAS HANDLED AND WONDERED IF INSURANCE FRAUD WAS BEING PLAYED OUT. WE ARE FOLLOWING THRU WITH THE STATE INSURANCE DEPT.] WHEN THE CLAIM WAS DENIED THE DEALER TOLD US TO TAKE THE VEHICLE TO WHERE WE PURCHASED IT BECAUSE THEY THEN DETERMINED THAT IT WAS A CONVERSION VAN COMPANY ISSUE. WE TOOK THE VEHICLE TO OUR DEALERSHIP AND THEY DETERMINED THAT THE CONVERSION COMPANY INSTALLED 20 INCH RIMS/TIRES ON A VEHICLE WITH 16 INCH MAXIMUM RIM/TIRE REQUIREMENT PER ENGINEERING SPECS. THE QUESTIONS THAT ARISE NOW ARE: WHY DID THEY SELL TO US A VEHICLE WHICH DOES NOT MEET ENGINEERING SPECS? TO WHAT EXTENT WAS MY FAMILY AT RISK OR IN DANGER? HOW MANY OTHER FAMILIES ARE THERE WHO ARE POTENTIALLY AT RISK DUE TO THIS CONDITION? WHAT ARE THE CHANCES THAT THIS WON'T HAPPEN AGAIN? WHAT RECOURSE DO WE HAVE? WE CERTAINLY DO NOT WANT THAT VEHICLE BACK IF WE CANNOT HAVE THE 20 INCH RIMS/TIRES. [LOW PROFILE TIRES] 16 INCH RIMS/TIRES WILL TAKE AWAY FROM THE LOOK OF THE VEHICLE. *TR

NHTSA ODI #10197741

Official recalls

8

09V307000 · Equipment Adaptive/mobility

Jul 29, 2009

CUSTOMIZERS IS RECALLING 3 VANS EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE LIFTS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 403, "PLATFORM LIFT SYSTEM ACCESSIBLE FOR MOTOR VEHICLES," THE ANTI-STOW INTERLOCK MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER. THE PRESSURE SENSING SWITCH THAT DETECTS THE PRESENCE OF WEIGHT ON THE PLATFORM WAS NOT ADJUSTED TO THE NECESSARY SENSITIVITY LEVEL. THE LIFT COULD STOW EVEN THOUGH SOMEONE OR SOMETHING IS STILL ON THE LIFT.

Consequence & remedy

Consequence: A LIFT OCCUPANT CAN BE INJURED SHOULD THE LIFT BEGIN TO STOW UNINTENTIONALLY.

Remedy: CUSTOMIZERS IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PLEASE SEE 07E097). OWNERS MAY CONTACT RICON AT 1-818-267-3000.

09V270000 · Equipment Adaptive/mobility

Jul 6, 2009

MAIN MOBILITY IS RECALLING 185 MODEL YEAR 2005 THROUGH 2009 CHEVROLET EXPRESS AND GMC SAVANA VANS MANUFACTURED BETWEEN APRIL 1, 2005 AND JUNE 25, 2009, EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 404, "PLATFORM LIFT INSTALLATIONS IN MOTOR VEHICLES." THE THRESHOLD WARNING SYSTEM MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER IN A CERTAIN SPOT WITHIN THE DEFINED THRESHOLD AREA.

Consequence & remedy

Consequence: THE USER OF THE LIFT COULD BE INJURED SHOULD THE LIFT MOVE UNINTENTIONALLY.

Remedy: MAIN MOBILITY IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PLEASE SEE 07E095). OWNERS MAY CONTACT RICON AT 1-818-267-3000 OR MAIN MOBILITY AT 1-716-759-6811.

09V272000 · Equipment Adaptive/mobility

Jul 6, 2009

MAIN MOBILITY IS RECALLING 185 MODEL YEAR 2005 THROUGH 2009 CHEVROLET EXPRESS AND GMC SAVANA VANS MANUFACTURED BETWEEN APRIL 1, 2005 AND JUNE 25, 2009, EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 403, "PLATFORM LIFT INSTALLATIONS IN MOTOR VEHICLES." THE ANTI-STOW INTERLOCK MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER. THE PRESSURE SENSING SWITCH THAT DETECTS THE PRESENCE OF WEIGHT ON THE PLATFORM WAS NOT ADJUSTED TO THE NECESSARY SENSITIVITY LEVEL. THE LIFT COULD STOW EVEN THOUGH SOMEONE OR SOMETHING IS STILL ON THE LIFT.

Consequence & remedy

Consequence: THE USER OF THE LIFT COULD BE INJURED SHOULD THE LIFT MOVE UNINTENTIONALLY.

Remedy: MAIN MOBILITY IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PLEASE SEE 07E097). OWNERS MAY CONTACT RICON AT 1-818-267-3000 OR MAIN MOBILITY AT 1-716-759-6811.

09V049000 · Equipment Adaptive/mobility

Feb 6, 2009

MOBILITY IS RECALLING 86 MY 2005-2006 FORD E-SERIES AND CHEVROLET EXPRESS VAN EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 404, "PLATFORM LIFT INSTALLATIONS ON MOTOR VEHICLES." THE THRESHOLD WARNING SYSTEM MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER IN A CERTAIN SPOT WITHIN THE DEFINED THRESHOLD AREA.

Consequence & remedy

Consequence: THE USER OF THE LIFT COULD BE INJURED SHOULD THE LIFT MOVE UNINTENTIONALLY.

Remedy: MOBILITY IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PLEASE SEE 07E095). OWNERS MAY CONTACT RICON AT 1-818-267-3000 OR MOBILITY AT 714-674-0480.

09V050000 · Equipment Adaptive/mobility

Feb 6, 2009

MOBILITY IS RECALLING 43 MY 2005-2006 FORD E-SERIES AND CHEVROLET EXPRESS VANS EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE LIFTS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 403, "PLATFORM LIFT SYSTEM ACCESSIBLE FOR MOTOR VEHICLES." THE ANTI-STOW INTERLOCK MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER. THE PRESSURE SENSING SWITCH THAT DETECTS THE PRESENCE OF WEIGHT ON THE PLATFORM WAS NOT ADJUSTED TO THE NECESSARY SENSITIVITY LEVEL. THE LIFT COULD STOW EVEN THOUGH SOMEONE OR SOMETHING IS STILL ON THE LIFT.

Consequence & remedy

Consequence: A LIFT OCCUPANT CAN BE INJURED SHOULD THE LIFT BEGIN TO STOW UNINTENTIONALLY.

Remedy: MOBILITY IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PLEASE SEE 07E097). OWNERS MAY CONTACT RICON AT 1-818-267-3000 OR MOBILITY AT 714-674-0480.

05V558000 · Seat Belts

Dec 19, 2005

ON CERTAIN FULL-SIZE PASSENGER, CARGO, OR CUTAWAY VANS, THE FRONT AND REAR SEAT BELT BUCKLES WILL NOT LATCH OR WILL NOT UNLATCH.

Consequence & remedy

Consequence: IN THE EVENT OF A CRASH, A SEAT OCCUPANT MAY NOT BE PROPERLY RESTRAINED INCREASING THE RISK OF PERSONAL INJURY.

Remedy: DEALERS WILL INSPECT THE BUCKLES AND, IF FOUND TO BE INOPERATIVE, THE ENTIRE BUCKLE ASSEMBLY WOULD BE REPLACED. FOR BUCKLES FOUND TO BE OPERATIVE, DEALER WILL REPLACE ONLY THE UPPER BUCKLE COVER. THE RECALL WILL BE CONDUCTED IN PHASES. THE FIRST PHASE MAILING BEGAN DURING MARCH 2006. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438 OR GMC AT 1-866-996-9463.

05V530000 · Exterior Lighting

Nov 7, 2005

CERTAIN CONVERSION VANS BUILT ON GMC/CHEVROLET CHASSIS FAIL TO COMPLY WITH REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES AND ASSOCIATED EQUIPMENT." THE HOUSING LENS OF THE CENTER HIGH MOUNTED STOP LAMP DOES NOT ALLOW ENOUGH LIGHT TO EMIT FROM THE LAMP.

Consequence & remedy

Consequence: FOLLOWING VEHICLES MAY NOT BE FULLY INFORMED OF VEHICLE BRAKING. REAR-END COLLISIONS AND INJURY TO OCCUPANTS MAY OCCUR.

Remedy: SANTA FE IS WORKING WITH AUDIOVOX TO REPLACE THE CENTER HIGH-MOUNTED BRAKE LAMP ASSEMBLY. OWNERS MAY CONTACT SANTA FE AT 1-800-274-1886 OR ASA AT 1-574-266-3172.

05V043000 · Service Brakes, Hydraulic

Feb 8, 2005

CERTAIN TRUCKS, SPORT UTILITY VEHICLES, AND VANS EQUIPPED WITH BOSCH HYDRO-BOOST BRAKE ASSEMBLIES, THE HYDRAULIC BRAKE BOOSTER PRESSURE ACCUMULATOR MAY CRACK AND SEPARATE FROM THE HYDRO-BOOST ASSEMBLY DURING NORMAL OPERATING CONDITIONS.

Consequence & remedy

Consequence: IF A SEPARATION OCCURRED AND THE HOOD OF THE VEHICLE WERE OPEN, FRAGMENTS FROM THE ACCUMULATOR COULD CAUSE INJURY TO PEOPLE IN THE IMMEDIATE AREA. THE PRESENCE OF THIS CRACK OR FRACTURED SURFACE COULD ALLOW THE HYDRAULIC FLUID TO LEAK FROM THE ACCUMULATOR CIRCUIT OF THE BOOSTER ASSEMBLY. THE LOSS OF FLUID WOULD CAUSE INCREASED STEERING AND BRAKING EFFORT AND A CRASH MAY OCCUR WITHOUT PRIOR WARNING.

Remedy: DEALERS WILL TEST THE HYDRO-BOOST ASSEMBLY FOR FUNCTIONAL OPERATION OF THE TWO-FUNCTION VALVE. IF THE HYDRO-BOOST ASSEMBLY FAILS THE TEST, DEALERS WILL REPLACE THE ASSEMBLY FREE OF CHARGE. THE RECALL BEGAN ON MARCH 23, 2005. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438, GMC TRUCKS AT 1-866-996-9463 AND HUMMER AT 1-800-732-5493.

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.