2005 Chevrolet Express

23 complaints on file, page 1 of 2.

1. Filed May 8, 2026Failure May 4, 2026Williamsport, PATires

   LT245/75R16. Driving north on I-77 around Charlotte, NC around 7:40 PM and the tire blew out. I saw in my left rearview mirror the treads roll off the right side of the highway. I did not run over anything. Travel speed was 65 to 70 mph in medium traffic. No warning lights came on. Did not lose control and was able to navigate to the left side of highway when enough space opened up after a guide rail. All that was left was the rim and shredded sidewalls. Tire was installed in August, 2025 and had just about 3000 miles on it when the blowout occurred. The passenger side of the vehicle was about 3 feet from the fog line, and traffic for the exit ramp was very close to the vehicle. Called 911 and NCDOT helped remove the rim and put on the spare. My wife and daughter were in the vehicle.

   NHTSA complaint 11736689
2. Filed Apr 11, 2026Failure Apr 10, 2026Mascott, FLService brakes

   I was driving and out of no where my brakes “ all four wheels “ locked up as if I was hauling a heavy load . I put on my hazard lights to warn the semi behind me. So I maintained control of my line until the cargo van slowed down to a safe speed for me to pull over . I thought the semi was going to run into the back of me, luckily the southbound line was clear so the semi took off pass me. So as I was coming to a safe stopping speed my brake pedal was stiff as well and when the cargo van slowed down to a safe speed, I pulled over to check my brakes with a warm liquid “ all four brakes were hot “ .

   NHTSA complaint 11730511
3. Filed Nov 24, 2025Failure Nov 23, 2025Drexel Hill, PAAir bags, Service brakes1 injured

   I was in a front end Collison due to a brake failure and when I have a steel gate at about 30 mph no airbag deployed. Car was towed by the Upper Darby Police Department and it is totaled. I sustained injuries. There was no airbag light brake warning light came when I attempted to use the emergency brake when regular failed

   NHTSA complaint 11701219
4. Filed Sep 29, 2022Failure Sep 22, 2022200,000 milesFayetteville, NCHeadlights, Suspension

   The contact owns a 2005 Chevrolet Express. The contact stated that while driving, the front passenger’s side tire started to wobble. The vehicle was taken to an independent mechanic and the contact was informed that the tie rod needed to be replaced. The vehicle was repaired. Additionally, the contact stated that while driving, the headlights failed to operate without engaging the lever. The vehicle was taken to an independent mechanic where the bulbs were replaced; however, the high-beam headlights failed to operate as needed. The vehicle was not repaired. Neither the dealer nor the manufacturer was notified of the failure. The failure mileage was approximately 200,000.

   NHTSA complaint 11487063
5. Filed Sep 8, 2022Failure Aug 1, 2022Plymouth, MNElectrical system, Service brakes

   Hole warn in front passenger side brake line from battery cable going to engine starter motor. The shielding on electrical cable rubbed and wore a hole in the brake line causing fluid to flow out and caused brakes to fail. No one was injured and no accident. I was backing out of the driveway the brakes failed, next I saw a large puddle of fluid on driveway, I just put it in park. The battery cable crosses over the break line and both are fastened to the frame near each other. I can provide break line and photo. The van has 60,000 miles on it, I purchased it new in 2005.

   NHTSA complaint 11483591
6. Filed Jun 18, 2021Failure Jun 17, 2021Kealakekua, HIBody

   Paint is peeling from ALL parts of the exterior vehicle, even around the window frames and door frames! It appears that NO PAINT PRIMER was used, at all! My white van has missing paint from about 75% of the vehicle, with bubbling going on, in the remainder of paint that has yet to fall off! Looking at ANY Chevy van that is on the roadways, one can easily see that the paint has also been falling off those vehicles, as well! This is a well-known defect in the painting practices of most ALL Chevrolet Vans, and should be dealt with on a class-action basis, since all Chevrolet Van owners are forced to live with an inferior paint scheme on these vehicles! But new owners are not aware of these shortcomings, until they see the paint fall off their vans, for no apparent reason! And it is clearly seen that NO PAINT PRIMER was used, when you look at the paint chip that fell off! Shame on Chevrolet and shame on the NHTSA agency for allowing any auto manufacturer to put out such inferior products to unsuspecting consumers!

   NHTSA complaint 11421445
7. Filed Mar 12, 2021Failure Mar 5, 2021230,000 milesReading, PAWheels

   BOTH REAR TIRES VEERUBBER TAIGA H/T SIZE LT 245/75R16 DOT # 6MSG-CH HAD BECOME UNSERVICEABLE DUE THE INSIDE SIDE WALL BELT PLYS SEPARATING RENDERING THE VEHICLE UNSAFE TO OPERATE. THE TIRES WERE REPLACED ON 5 MAR 2021 WITH NEW COPPER STFR SOLARUS LT245/75R16 THROUGH MAVIS TIRE WHICH HAD INSTALLED THE TAIGA TIRES MENTIONED ABOVE ON 21 MAY 2020. THIS IS UNACCEPTABLE FOR THESE TIES SINCE THEY ONLY APPROXIMATELY 15000 MILES ON THEM AND THEY HAD A SERVICE LIFE OF 45000 MILES. THIS ISSUE CAME TO LIGHT WHEN WE WERE OPERATING OUR VAN ON A HIGHWAY TRAVELING AT APPROXIMATELY 60 MILES AN HOUR.

   NHTSA complaint 11402633
8. Filed Mar 7, 2019Failure Mar 5, 201936,400 milesKenosha, WIElectronic stability control (esc)

   WHEN DRIVING ON DRY PAVEMENT THE TRACTION CONTROL OR STABILITRAK WILL KICK ON AND IT PULLS TO THE RIGHT REALLY HARD ON AND OFF AND ITS HARD TO CONTROL THE VEHICLE. THE FIRST TIME IT HAPPENED I ACTUALLY THOUGHT I HAD A FLAT TIRE. WHEN THIS IS HAPPENING IT FEELS LIKE THE ANTI-LOCK BRAKES ALSO KICK IN AS IT IS VERY HARD TO STOP ALSO. I HAVE HAD THIS HAPPEN AT 45MPH AND ITS TERRIFYING IM AFRAID IF THIS HAPPENED AT 70MPH IT WOULD CAUSE YOU TO LOSE CONTROL OF THE VEHICLE

   NHTSA complaint 11184774
9. Filed Dec 7, 2015Failure Jul 20, 200623,000 milesWesley Chapel, FLBody

   PAINT PEELING OFF, HAS BEEN FOR YEARS.

   NHTSA complaint 10808700
10. Filed Dec 20, 2014Failure Apr 15, 2014115,060 milesPark Forest, ILExterior lighting, Service brakes, Suspension

    THE BRAKES ON MY VEHICLE WERE INSPECTED AT HOMEWOOD CHEVROLET IN ILLINOIS AND THEY DID NOT NEED PADS OR ANYTHING, HOWEVER, THE BRAKES BRAKES RELEASE ON THEIR OWN WHEN YOU ARE DRIVING. THERE WAS A HYDRAULIC RECALL AND I NEVER RECEIVED ANY INFORMATION..THE HEADLIGHTS ON MY CAR ALSO KEEP BURNING OUT WITHIN WEEKS OF HAVING THEM CHANGED. THE VEHICLE HAS SOME SUSPENSION ISSUE AS WELL. THERE WAS ALSO A RECALL FOR THAT WHICH I RECEIVED NO NOTICE FOR.I HAVE NOT MOVED SINCE PURCHASING THIS VEHICLE.

    NHTSA complaint 10667416
11. Filed Oct 26, 2014Failure May 15, 201392,000 milesScottsdale, AZBody

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

    NHTSA complaint 10650140
12. Filed Jun 30, 2014Failure Aug 15, 2013101,000 milesBuffalo, NYElectrical system

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

    NHTSA complaint 10607157
13. Filed Jun 23, 2014Failure Jun 23, 201482,868 milesLewiston, MEFuel 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 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 complaint 10605303
14. Filed Oct 23, 2013Failure Oct 1, 2013155,000 milesOrland Park, ILSeat 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 complaint 10549184
15. Filed Jul 10, 2012Failure Jun 10, 2012130,000 milesNeshotah, WIElectrical system, Fuel/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 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 complaint 10465046
16. Filed Jun 7, 2012Failure Jun 7, 201289,000 milesBoca Raton, FLBody

    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 complaint 10460964
17. Filed Jan 18, 2012Failure Jan 14, 201270,000 milesJacksonville, FLElectrical 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 FOR FURTHER INVESTIGATION. THE FAILURE AND THE CURRENT MILEAGE WAS 70,000.

    NHTSA complaint 10444339
18. Filed Apr 28, 2009Failure Apr 24, 200958,000 milesGettysburg, PAService 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 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 complaint 10267068
19. Filed Dec 20, 2007Failure Jun 20, 20072,700 milesHighland, NYService brakes, Antilock/traction control/electronic limited slip, Tie rod assembly, Structure

    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 complaint 10212794
20. Filed Jul 28, 2007Failure Jun 20, 200727,000 milesHighland, NYShock absorber, Rim

    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 complaint 10197741