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
165,000 miles · Nov 12, 2008
Seat Belts
TL*THE CONTACT OWNS A 2005 CHEVROLET EXPRESS 3500. THE CONTACT STATED THAT THE RELEASE BUTTON ON THE PASSENGER SIDE SEAT BELT FAILED. AS A RESULT, THE PASSENGER WAS TRAPPED IN THE SEAT BELT FOR THIRTY MINUTES. SHE HAD TO REMOVE A SCREW FROM THE SEAT IN ORDER TO LIFT THE SEAT BELT OVER HER HEAD. CURRENTLY, THE RELEASE BUTTON …
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TL*THE CONTACT OWNS A 2005 CHEVROLET EXPRESS 3500. THE CONTACT STATED THAT THE RELEASE BUTTON ON THE PASSENGER SIDE SEAT BELT FAILED. AS A RESULT, THE PASSENGER WAS TRAPPED IN THE SEAT BELT FOR THIRTY MINUTES. SHE HAD TO REMOVE A SCREW FROM THE SEAT IN ORDER TO LIFT THE SEAT BELT OVER HER HEAD. CURRENTLY, THE RELEASE BUTTON FOR THE BUCKLE HAS STILL NOT RELEASED. THE MANUFACTURER SENT A SPECIALIST, WHO STATED THAT THEY WOULD NOT ASSIST IN THE REPAIR; HOWEVER, THERE WAS A PRIOR RECALL FOR THIS FAILURE THAT HAD BEEN PREVIOUSLY REPAIRED. THE DEALER STATED THAT THE FAILURE WAS CAUSED BY THE BUCKLE. THE VEHICLE HAS NOT BEEN REPAIRED. THE NHTSA CAMPAIGN ID NUMBER WAS UNKNOWN. THE CURRENT AND FAILURE MILEAGES WERE APPROXIMATELY 165,000.
NHTSA ODI #10248586
Mileage unknown · Jul 30, 2008
SteeringStructure
THIS VEHICLE HAS A SERIOUS SAFETY ISSUE THAT DIRECTLY EFFECTS ITS CHASSIS AND STEERING IDLER ARM. WORST CASE SENERIO WOULD BE THE LOSS OF STEERING CAPABILITY WHICH COULD LEAD TO SERIOUS PHYSICAL INJURY AND/OR FATALITY. MANUFACTURE HAS DOWN PLAYED THIS SAFETY ISSUE WHEREAS MY PHOTOGRAPH AND DOCUMENTATION OF AN ENGINEERING / MANUF…
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THIS VEHICLE HAS A SERIOUS SAFETY ISSUE THAT DIRECTLY EFFECTS ITS CHASSIS AND STEERING IDLER ARM. WORST CASE SENERIO WOULD BE THE LOSS OF STEERING CAPABILITY WHICH COULD LEAD TO SERIOUS PHYSICAL INJURY AND/OR FATALITY. MANUFACTURE HAS DOWN PLAYED THIS SAFETY ISSUE WHEREAS MY PHOTOGRAPH AND DOCUMENTATION OF AN ENGINEERING / MANUFACTURING DEFECT WOULD SERIOUSLY CONTRADICT ANY EXPLANATION OFFERED BY THE MANUFACTURE, WHICH TO INCLUDE THE MERE MANUFACTURES "GENERAL MOTORS" SPECIAL COVERAGE ADJUSTMENT - STEERING IDLER ARM, RE:DOCUMENT ID#1976266. WHICH I WAS NEVER INFORMED OF UNTIL THE VEHICLE WAS PRESENTED FOR A NEWYORK STATE DEPARTMENT OF MOTOR VEHICLE INSPECTION. UPON REQUEST I WILL PRODUCE GM WORK ORDER TICKETS, PHOTOGRAPHS, TAP-RECORDINGS OF GM TECHNICIANS AND GM EMPLOYEES WHO ARE ASSIGNED TO THE GM CUSTOMER CARE DIVISION WHOM WERE LATER DISCOVERED TO BE EMPLOYEES EMPLOYED AT THE GENERAL MOTORS LEGAL DIVISION WHOM TO DATE HAVE INTENTIONAL AVOID THIS ISSUE AND REFUSES TO HAVE A GM TERRITORIAL ENGINEER INSPECT THIS VEHICLE TO SIGN OFF ON THE VEHICLES SAFE OPERATION. THIS IS A SERIOUS SAFETY ISSUE THAT NEEDS TO BE INVESTIGATED FURTHER TO INSURE PUBLIC SAFETY AND VEHICLE OPERATOR SAFETY. *TR
NHTSA ODI #10236362
125 miles · Mar 4, 2008
Fuel System, GasolinePower TrainTires
TL*THE CONTACT OWNS A 2005 CHEVROLET EXPRESS 3500. THE VEHICLE HAS A WOOD FLOOR THAT SHRINKS AND ALLOWS CARBON MONOXIDE TO PENETRATE INTO THE PASSENGER COMPARTMENT. THE CONTACT BECOMES NAUSEOUS WHILE DRIVING. THE DEALER STATED THAT THE FAILURE WAS THE MANUFACTURER'S RESPONSIBILITY; HOWEVER, THE MANUFACTURER STATED THAT THEY W…
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TL*THE CONTACT OWNS A 2005 CHEVROLET EXPRESS 3500. THE VEHICLE HAS A WOOD FLOOR THAT SHRINKS AND ALLOWS CARBON MONOXIDE TO PENETRATE INTO THE PASSENGER COMPARTMENT. THE CONTACT BECOMES NAUSEOUS WHILE DRIVING. THE DEALER STATED THAT THE FAILURE WAS THE MANUFACTURER'S RESPONSIBILITY; HOWEVER, THE MANUFACTURER STATED THAT THEY WERE NOT RESPONSIBLE BECAUSE ANOTHER COMPANY DESIGNED THE VEHICLE. THE CONTACT ALSO STATED THAT THE TIRES WERE WEARING FASTER THAN NORMAL, THE TRANSMISSION HESITATES, AND THE VEHICLE SHAKES. THE VEHICLE WAS PURCHASED NEW IN 2005 AND THE DEALER HAS NOT OFFERED ANY ASSISTANCE. THE CURRENT MILEAGE WAS 50,000 AND FAILURE MILEAGE WAS 125.
NHTSA ODI #10220077
Mileage unknown · Oct 24, 2007
Fuel System, GasolineStructure
2005 CHEVY EXPRESS 3500 WITH DEFECTIVE FUEL TANK PARTS. CONSUMER STATED THAT HE SMELLED GAS AND THEN A FEW MONTHS LATER SAW IT. MECHANIC DETERMINED IT WAS THE GAS TANK ALONG WITH THE GASKETS THAT WERE DEFECTIVE. *KB THE SEAL AT THE BASE OF THE VALVE WAS NOT CORRECTLY SEALED. RUST WAS REMOVED FROM THE DOOR HINGE.*JB
NHTSA ODI #10207217
23,000 miles · May 21, 2007
SteeringCrash
TL*THE CONTACT OWNS A 2005 CHEVROLET EXPRESS 15 PASSENGER VAN. WHILE DRIVING 25MPH THERE WAS A POPPING SOUND IN THE STEERING WHEEL WHEN MAKING A LEFT TURN. THE STEERING BOX ALSO SEPARATED FROM THE FRAME. ON 5/4/07, THE DEALER STATED THAT THE VEHICLE WAS OPERATING NORMALLY. ON 5/15/07 WHILE DRIVING 25 MPH IN A TUNNEL ON A HILL …
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TL*THE CONTACT OWNS A 2005 CHEVROLET EXPRESS 15 PASSENGER VAN. WHILE DRIVING 25MPH THERE WAS A POPPING SOUND IN THE STEERING WHEEL WHEN MAKING A LEFT TURN. THE STEERING BOX ALSO SEPARATED FROM THE FRAME. ON 5/4/07, THE DEALER STATED THAT THE VEHICLE WAS OPERATING NORMALLY. ON 5/15/07 WHILE DRIVING 25 MPH IN A TUNNEL ON A HILL THE VEHICLE BEGAN SHAKING OUT OF CONTROL. THE DRIVER WAS FORCED TO APPLY EXTREME PRESSURE TO THE BRAKES; HOWEVER, THE VEHICLE CRASHED INTO THE SIDEWALK INSIDE THE TUNNEL. THERE WERE NO PRIOR WARNINGS. THERE WERE NO INJURIES. THE ENGINE SIZE, NUMBER OF CYLINDERS AND PURCHASE DATE WERE NOT AVAILABLE. THE CURRENT AND FAILURE MILEAGE WERE 2,300.
NHTSA ODI #10191393
Mileage unknown · Jun 9, 2006
Visibility
I DRIVE A 2005 3500 CHEVY EXPRESS VAN THAT HAS A DRIVER'S SIDE MIRROR THAT MOVES WHILE DRIVING AT HIGHWAY SPEEDS. I TOOK THE VAN TO THE LOCAL DEALER WHO STATED THEY ORDERED AND REPLACED THE MIRROR. AFTER PICKING UP THE VAN I NOTICED IT WAS NO DIFFERENT. I TOOK IT BACK AND THEY TOLD ME THERE WAS NOTHING THEY COULD DO. I FEEL THIS…
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I DRIVE A 2005 3500 CHEVY EXPRESS VAN THAT HAS A DRIVER'S SIDE MIRROR THAT MOVES WHILE DRIVING AT HIGHWAY SPEEDS. I TOOK THE VAN TO THE LOCAL DEALER WHO STATED THEY ORDERED AND REPLACED THE MIRROR. AFTER PICKING UP THE VAN I NOTICED IT WAS NO DIFFERENT. I TOOK IT BACK AND THEY TOLD ME THERE WAS NOTHING THEY COULD DO. I FEEL THIS IS A SAFETY ISSUE BECAUSE AT HIGHWAY SPEEDS IT IS DIFFICULT TO SEE VEHICLES COMING UP BESIDE ME. I WOULD LIKE HELP IN GETTING THE PROBLEM SOLVED. *JB
NHTSA ODI #10159403
800 miles · Jun 17, 2005
Seat Belts
SEATBELETS IN 2005 CHEVROLET 15 PASSANGER VAN MALFUNCTIONED, SEVERAL TRAPPED PERSONS IN SEAT AND HAD TO BE CUT OUT.
NHTSA ODI #10125659
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.
2005 Chevrolet Express 3500 Problems, Complaints & Recalls | Skip That Year