NHTSA vehicle safety data

2005 Chevrolet Express 2500 Recalls & Complaints

The 2005 Chevrolet Express 2500 has 1 NHTSA recall campaign and 9 owner complaints on file as of November 3, 2026. Recall repairs are usually free at an authorized Chevrolet dealer.

NHTSA recall and complaint data for the 2005 Chevrolet Express 2500. Recall data is refreshed daily from NHTSA.

2005 Chevrolet Express 2500 owner complaints

Owners have filed 9 complaints with NHTSA about the 2005 Chevrolet Express 2500, describing incidents dated December 20, 2004 to July 9, 2015.

Most-cited components

Structure 3 complaints
Tires 2 complaints
Air Bags 1 complaint
Equipment Adaptive/Mobility 1 complaint
Exterior Lighting 1 complaint
Latches/Locks/Linkages 1 complaint

Of the 9 complaints on file, 2 report a crash and 1 a fire; across all 9 complaints, owners report 1 injury (owner-reported, not verified by NHTSA).

Newest complaints

ODI #10733922 · Filed July 14, 2015
CATASTROPHIC SIDEWALL FAILURE IN TIRE WHILE TRAVELING IN TRAFFIC AT 50MPH. DRIVER SIDE REAR TIRE COMPLETELY FAILED AND UPON REMOVAL- NOTICED SIDEWALL SPLIT. UPON IMMEDIATE INSPECTION OF PASSENGER REAR TIRE, NOTICED SAME SPLIT IN SIDEWALL OF TIRE, WITH FAILURE IMPENDING. 55.000 MILETIRES HAVE 31000…
ODI #10542111 · Filed September 5, 2013
VEHICLE WAS TAKEN IN FOR INSPECTION AND FAILED DUE TO THE TRANSMISSION CROSS MEMBER RUSTING OUT. IT IS 7 YEARS OLD BUT HAS LOW MILEAGE. I DO NOT FEEL THAT FAILURE OF THE FRAME SHOULD HAPPEN I WAS TOLD THAT THIS FAILURE DUE TO RUST IS COMMON ON THESE VANS AND THEY MAKE A REPLACEMENT CROSS MEMBER THAT…
ODI #10532018 · Filed July 26, 2013
PASSENGER SIDE DOUBLE DOOR HINGES GOT SO TIGHT THAT THEY SNAPPED THE HINGE. NO LUBE WOULD LOOSEN PRIOR TO BREAKING. THIS WEEK THE RIGHT DOOR EXACT SAME THING. HINGE SNAPPED. THE ORIGINAL HINGES ARE DEFECTIVE AND ARE UNABLE TO BE LUBED. THEY KNOW THEY HAVE A PROBLEM BECAUSE THE NEW ONES ARE MADE WITH…

Read all 9 complaints

AFTERMARKET FUEL FILTERS/FUEL LEAK

NHTSA #06E043000 · Fuel System, Gasoline · NHTSA notice

Reported May 19, 2006 · HONEYWELL INTERNATIONAL, INC.

Potentially affected: 88,303 vehicles

Owners notified October 18, 2006

Defect description

CERTAIN REPLACEMENT FUEL FILTERS, FRAM BRAND NAME P/N G3727, WITH DATE CODES X52911 THROUGH X60801 SEQUENTIALLY OR X600141 AND A MEXICO COUNTRY OR ORIGIN MARKING ON THE FUEL FILTER HOUSING MANUFACTURED FROM OCTOBER 18, 2005, THROUGH MARCH 21, 2006, SOLD FOR USE ON THE VEHICLES LISTED ABOVE AND ON CERTAIN SCHOOL BUSES. (TO SEE THE SCHOOL BUS ENGINE SIZES, CLICK ON "DOCUMENT SEARCH" AND THEN "BUS APPLICATIONS"). THE CONNECTOR ON THE FUEL FILTER WAS NOT MANUFACTURED TO HONEYWELL'S SPECIFICATION. AS A RESULT, THE O-RING MAY NOT SEAT CORRECTLY ON THE FUEL LINE.

Safety consequence

THIS CONDITION MAY CAUSE AN INADEQUATE SEAL AT THE CONNECTION, POTENTIALLY LEADING TO A FUEL LEAK. IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.

Manufacturer remedy

HONEYWELL WILL NOTIFY OWNERS AND REPLACE THE FUEL FILTERS FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 18, 2006. OWNERS MAY CONTACT FRAM CUSTOMER SERVICE AT 1-800-890-2075 (OPTION 1).

Notes

THIS RECALL ONLY PERTAINS TO AFTERMARKET FRAM FUEL FILTERS AND HAS NO RELATION TO ANY ORIGINAL EQUIPMENT INSTALLED ON THE VEHICLES LISTED.CUSTOMERS MAY CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.

try.vin has no NCAP crash-test rating on file for the 2005 Chevrolet Express 2500. NHTSA rates some vehicles by body style — pickups by cab, vans by roof height — so check nhtsa.gov/ratings.

9 owner complaints have been filed with NHTSA for the 2005 Chevrolet Express 2500.

Tires

ODI #10733922

Incident: July 9, 2015 · Filed: July 14, 2015

CATASTROPHIC SIDEWALL FAILURE IN TIRE WHILE TRAVELING IN TRAFFIC AT 50MPH. DRIVER SIDE REAR TIRE COMPLETELY FAILED AND UPON REMOVAL- NOTICED SIDEWALL SPLIT. UPON IMMEDIATE INSPECTION OF PASSENGER REAR TIRE, NOTICED SAME SPLIT IN SIDEWALL OF TIRE, WITH FAILURE IMPENDING. 55.000 MILETIRES HAVE 31000 MILES- ROTATED NORMALLY, AIR PRESSURE AS PER RECOMMENDATIONS. MAIN PROBLEM- THERE ARE 2 MORE TIRES ON THE FRONT- SAME MANUFACTURE AND MAKE- CLASSIFICATION RATING.

Structure

ODI #10542111

Incident: September 4, 2013 · Filed: September 5, 2013

VEHICLE WAS TAKEN IN FOR INSPECTION AND FAILED DUE TO THE TRANSMISSION CROSS MEMBER RUSTING OUT. IT IS 7 YEARS OLD BUT HAS LOW MILEAGE. I DO NOT FEEL THAT FAILURE OF THE FRAME SHOULD HAPPEN I WAS TOLD THAT THIS FAILURE DUE TO RUST IS COMMON ON THESE VANS AND THEY MAKE A REPLACEMENT CROSS MEMBER THAT BOLTS RIGHT IN BECAUSE OF THIS PROBLEM. I HAVE ALREADY HAD TO REPLACE ABS SENSORS DUE TO CORROSION AND NOW THIS, BOTH ARE SAFETY PARTS AND FAILED BECAUSE THEY ARE NOT DESIGNED FOR THE NORMAL WEAR AND TEAR IN NORTHERN STATES. *JB

Structure

ODI #10532018

Incident: July 26, 2013 · Filed: July 26, 2013

PASSENGER SIDE DOUBLE DOOR HINGES GOT SO TIGHT THAT THEY SNAPPED THE HINGE. NO LUBE WOULD LOOSEN PRIOR TO BREAKING. THIS WEEK THE RIGHT DOOR EXACT SAME THING. HINGE SNAPPED. THE ORIGINAL HINGES ARE DEFECTIVE AND ARE UNABLE TO BE LUBED. THEY KNOW THEY HAVE A PROBLEM BECAUSE THE NEW ONES ARE MADE WITH GREASE FITTINGS. I JUST LOOKED ON LINE AT A FORUM AND THERE ARE SEVERAL LISTINGS FOR THE SAME PROBLEM FOR YEARS. *TR

Structure; Latches/Locks/Linkages

ODI #10366777

Incident: November 17, 2010 · Filed: November 18, 2010

LAST YEAR PASSENGER SIDE DOUBLE DOOR LEFT SIDE HINGES GOT SO TIGHT THAT THEY SNAPPED THE HINGE. NO LUBE WOULD LOOSEN PRIOR TO BREAKING. THIS WEEK THE RIGHT DOOR EXACT SAME THING. HINGE SNAPPED. REPLACED THIS ONE COSTING ME $800. LAST YEAR WAS PROBABLY THE SAME COST FOR THE LEFT. THE ORIGINAL HINGES ARE DEFECTIVE AND ARE UNABLE TO BE LUBED. THEY KNOW THEY HAVE A PROBLEM BECAUSE THE NEW ONES ARE MADE WITH GREASE FITTINGS. I JUST LOOKED ON LINE AT A FORUM AND THERE ARE SEVERAL LISTINGS FOR THE SAME PROBLEM FOR YEARS. *TR

Equipment Adaptive/Mobility

ODI #10334439

Incident: January 19, 2007 · Filed: June 3, 2010

TL* THE CONTACT OWNS A 2005 CHEVROLET EXPRESS 2500 VAN. THE CONTACT STATED THAT THE PASSENGERS SIDE CLAM SHELL DOOR HINGES WERE DEFECTIVE AND WERE DIFFICULT TO OPEN. INTERMITTENTLY, THE DOOR WOULD BECOME STUCK. THE DEALER WAS CONTACTED AND ADVISED ALTHOUGH THERE WAS A RECALL FOR THE FAILURE, THE CONTACTS VIN WAS NOT INCLUDED IN THE RECALL (NHTSA CAMPAIGN ID NUMBER 09V307000: EQUIPMENT ADAPTIVE).THE FAILURE AND CURRENT MILEAGES WERE APPROXIMATELY 26,000.

Exterior Lighting

ODI #10310907

Incident: February 15, 2010 · Filed: February 16, 2010

THE HEADLIGHT SWITCH IS FAULTY...WORKS INTERMITTENTLY. *TR

Air Bags; Seat Belts

ODI #10223908

Crash 1 injury

Incident: February 12, 2008 · Filed: April 3, 2008

2005 CHEVROLET EXPRESS WITH SEATBELT AND AIRBAG FAILURE. CONSUMER STATES THAT WHEN THE ACCIDENT OCCURRED THE SEATBELT DID NOT RETRACT AND THE AIRBAGS DID NOT DEPLOY. CONSUMER WOULD LIKE TO KNOW IF SIMILAR ACCIDENTS HAVE OCCURRED. *KB (LAWYER WROTE IN ON BEHALF OF CLIENT). *JB

Suspension; Power Train

ODI #10222291

Crash Fire

Incident: December 22, 2007 · Filed: March 25, 2008

THE LEFT FRONT WHEEL BEARING CAME APART WITH ONLY 45,000 MILES ON THE VEHICLE. I WAS ON I-40 IN A 70 MPH ZONE I WAS VERY LUCKY THAT THE VAN DID NOT ROLL OVER. *TR

Tires

ODI #10104254

Incident: December 20, 2004 · Filed: December 21, 2004

NEW 2005 CHEVY EXPRESS CARGO VAN 3/4 TON. BRIDGESTONE TIRE 245 75 16. NO TRACTION AND POOR STEERING AND STOPPING CAPABILITIES DURING ANY AMOUNT OF SNOW ON ROADS. *AK

Other Chevrolet Express 2500 model years

Check your 2005 Chevrolet Express 2500 VIN

Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your Chevrolet Express 2500 at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.

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