Model year record

2005 Chevrolet Express 1500 recalls & problems

The 2005 Chevrolet Express 1500 has 1 safety recall and 10 owner complaints on file with NHTSA. The most-reported problem area is service brakes, hydraulic (3 complaints).

Recalls1safety recalls

Complaints10filed by owners

Crashes · fires2 · 0reported in complaints

Injuries · deaths1 · 0reported in complaints

Safety recalls

Fuel system, gasolineMay 19, 2006

Fuel system, gasoline

Recall 06E04300088,303 vehicles

Problem: 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.
Risk: 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.
Fix: 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).

Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.

Fuel economy

Express 1500 AWD

14mpg combined

City / highway	13 / 17 mpg
Fuel	Regular Gasoline

5.3 L · 8 cyl · Automatic 4-spd · 4-Wheel or All-Wheel Drive · about $4,800/year to fuel

EPA estimates from fueleconomy.gov for each engine and transmission sold. Annual cost is the EPA's estimate for 15,000 miles a year at its current fuel and electricity price assumptions. Your results will vary.

What owners report

Problem area	Complaints	Crashes	Injuries	Typical mileage*
Service brakes, hydraulicFoundation components › Master cylinder	3	1	0	53,000 mi
VisibilityRearview mirrors/devices › Exterior	1	0	0	—
Power trainTransfer case (4-wheel drive)	1	0	0	—
Air bags	1	1	1	—
Service brakes	1	0	0	—
Electrical system	1	0	0	—
Engine	1	0	0	—
Exterior lightingBrake lights	1	0	0	—

*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.

Recent owner complaints

Exterior lighting › Brake lights
TL* THE CONTACT OWNS A 2005 CHEVROLET EXPRESS 1500. THE CONTACT STATED THAT THE DRIVER SIDE BRAKE LIGHT FAILED WITHOUT WARNING. THE CONTACT REPLACED THE FUSE, BUT THE FAILURE RECURRED ON SEVERAL OCCASIONS. THE VEHICLE WAS TAKEN TO THE DEALER, BUT WAS NOT DIAGNOSED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 150,000.
Feb 1, 2015 · 150,000 miles
Engine
THIS COULD HAVE HAPPENED BEFORE AND JUST DIDN'T PAY THAT MUCH ATTENTION TO IT BUT THE FIRST TIME WE REALLY NOTICED IT WE WERE : TRAVELING SLOWLY ON GRAVEL ROAD , ENGINE JUST QUIT. HAD TO PUT VEHICLE IN PARK AND CRANK IT . SECOND TIME : HAD JUST STOPPED AT A STOP SIGN , STARTED TO PULL OUT, ENGINE JUST QUIT . HAD TO PUT VEHICLE IN PARK AND CRANK IT AGAIN. LUCKILY THERE WERE NO OTHER VEHICLES BEHIND US EITHER TIME . NEED TO USE THIS VEHICLE FOR A TRIP WITH OUR GRANDCHILDREN AND DO NOT FEEL SAFE OR COMFORTABLE IN TRAFFIC AS THIS COULD HAPPEN AGAIN AND COULD CAUSE AN ACCIDENT. WE HAVE NOT BEEN INFORMED IF THERE IS A RECALL ON THIS BUT FEEL THERE MUST BE SOME TYPE OF DEFECT AND THAT THIS IS A…
May 22, 2013 · 25,000 miles
Electrical system
TL* THE CONTACT OWNS A 2005 CHEVROLET EXPRESS 1500. THE CONTACT STATED THAT WHILE DRIVING 70 MPH, THE VEHICLE STALLED WITHOUT WARNING. AN INDEPENDENT MECHANIC DIAGNOSED THAT THE IGNITION MODULE FAILED, AND MADE THE NECESSARY REPAIRS. THE MANUFACTURER WAS NOTIFIED AND ADVISED THAT THERE WERE NO OPEN RECALLS FOR THE VEHICLE. THE APPROXIMATE FAILURE MILEAGE WAS 90,000.
May 16, 2012 · 90,000 miles
Service brakes
I WAS TRAVELING DOWN A HILL AT ABOUT 35-40 MPH. WHEN THE ABS SYSTEM KICKED IN FOR SOME REASON AND THE BRAKES WENT STIFF AND I COULD BARELY STOP. MECHANIC SAID WHEEL SENSOR, IT WAS CHANGED AND I HAVE THE SAME PROBLEM. THE ABS KICKS IN AT THE WORST TIMES WHEN YOU ARE SLOWING DOWN COMING TO AN INTERSECTION THE BRAKES GO STIFF. ALMOST GOT KILLED. *TR
Jun 21, 2013 · 157,200 miles
Air bagsCrash1 injury
THE AIRBAGS IN MY EXPRESS 1500 DID NOT DEPLOY AFTER I SKIDDED OUT ON A HIGHWAY TO AVOID A 18 WHEELER. THE VAN WAS TOTALED SO NOTHING WAS DONE TO CORRECT IT BUT WITH NO AIRBAGS IT LED TO A BROKEN SHOULDER AND SOME RIBS FROM THE STEERING WHEEL. I HIT THE JERSEY BARRIER GOING DIRECTLY STRAIGHT AT IT AT ABOUT 50-60MPH. *TR
Dec 12, 2010 · 235,000 miles
Service brakes, hydraulic › Foundation components › Master cylinderCrash
TL* THE CONTACT OWNS A 2005 CHEVROLET EXPRESS 1500. THE CONTACT WAS TRAVELING 25 MPH WHEN THE BRAKES WERE APPLIED AND THEY WOULD NOT RESPOND. THE CONTACT WAS FORCED THROUGH A RED TRAFFIC LIGHT AND ATTEMPTED TO SHIFT INTO A LOWER GEAR. THE VEHICLE DID NOT STOP UNTIL DRIVING OVER A CURVE AND COMING TO A STOP. THE VEHICLE WAS INSPECTED BY A MECHANIC WHERE IT WAS DISCOVERED THAT ONE OF THE HOSES OF THE MASTER CYLINDER FAILED. THE MECHANIC ADVISED THAT THERE WERE TWO HOSES THAT WERE RUNNING TOGETHER ABNORMALLY AND THE FRICTION CAUSED THE HOSE TO COLLAPSE. THE FAILURE AND CURRENT MILEAGE WAS 53,000.
Oct 1, 2010 · 53,000 miles
Service brakes, hydraulic
I OWN A 2005 CHEVROLET EXPRESS 1500 V6 AND WHILE DRIVING TO MY HOUSE FROM WORK I LOST ALL BRAKES DUE TO A BRAKE LINE FAILURE, THE TWO HYDRAULIC BRAKE HOSES THAT ARE ATTACHED TO THE MASTER CYLINDER ARE IN CONTACT WITH ANOTHER METALLIC BRAKE HOSE UNDER THEM, BY RUBBING TOGETHER FOR FOUR YEARS CAUSED THE HOSES TO WEAR AND RUPTURE AND NEARLY CAUSED A CRASH. *TR
Oct 2, 2010 · 53,800 miles
Power train › Transfer case (4-wheel drive)
TL* THE CONTACT OWNS A 2005 CHEVROLET EXPRESS 1500. WHILE DRIVING 65 MPH THE VEHICLE BEGAN TO VIBRATE. NEXT THE ABS LIGHT HAD ILLUMINATED ON THE INSTRUMENT CONTROL PANEL. THE VEHICLE WAS TAKEN TO THE DEALERSHIP AND THE TRANSFER CASE WAS REPLACED. THE CURRENT AND FAILURE MILEAGES WERE 28000. UPDATED 01/05/10. *LJ THE CONSUMER STATED THE VEHICLE BROKE DOWN 20 MINUTES AWAY FROM HOME. THE BRAKES LOCKED UP AND THE VEHICLE MADE A LOUD NOISE. THE CONSUMER WAS INFORMED THE SEAL FAILED ON THE TRANSFER CASE WHICH CAUSED ALL THE FLUIDS TO INTO THE TRANSMISSION. UPDATED 01/05/10. *JB
Nov 9, 2009 · 31,185 miles

Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.