Total Complaints
26 filings
CHEVROLET EXPRESS 3500 · model year
26 NHTSA complaints, 1 crash report, and 1 active recall for this specific cohort.
NHTSA overall rating
Not crash-tested
New Car Assessment Program
The 2005CHEVROLETEXPRESS 3500 carries 26 consumer safety complaints in NHTSA's Office of Defects Investigation database for this specific model-year cohort. Within that volume, owners reported 1 crash, 4 fires, 2 injuries, and 0 fatalities. No NCAP 5-star crash-test rating is available for this model year in the federal database.
Component-level analysis is where model-year complaints become actionable: the top complaint category for the 2005 EXPRESS 3500 is seat belts with 3 filings, followed by tires (3) and steering (2). Concentration in one or two component groups is the classic signature of a systemic defect; a flat distribution usually reflects normal aging, warranty complaints, or isolated build-plant variability. This model year has 1 active recall campaign, which means the manufacturer is obligated to remedy the covered defect at no charge for the life of the vehicle — the full NHTSA campaign numbers are listed below.
NHTSA currently has 57 investigation files overlapping the 2005 EXPRESS 3500, and 2 remain open. Owners comparing this cohort against neighboring years should pair the counters above with the complaint-by-year trend on the parent model page — a spike in a single year often tracks to a platform refresh, a new transmission supplier, or an updated ECU calibration. Use the related-complaint feed below to read raw owner narratives before deciding whether any pattern here affects your specific use case.
Total Complaints
26 filings
Crashes Reported
1 reports
Source
NHTSA ODI
Federal complaints database
At or below the fleet median complaint volume.
| Component | Count |
|---|---|
| SEAT BELTS | 3 |
| TIRES | 3 |
| STEERING | 2 |
| STRUCTURE | 2 |
| SERVICE BRAKES, HYDRAULIC | 2 |
| UNKNOWN OR OTHER | 2 |
| VISIBILITY:REARVIEW MIRRORS/DEVICES:EXTERIOR | 1 |
| FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY | 1 |
| STRUCTURE:BODY:DOOR:HINGE AND ATTACHMENTS | 1 |
| FUEL SYSTEM, GASOLINE | 1 |
| POWER TRAIN:AUTOMATIC TRANSMISSION | 1 |
| STRUCTURE:FRAME AND MEMBERS | 1 |
| STRUCTURE:BODY | 1 |
| SERVICE BRAKES | 1 |
| WHEELS | 1 |
FUEL SYSTEM, GASOLINE
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 CE
BF GOODRICH TIRE DOT BE11 JD11 4012 LT 24.5/75 R16 120/1160 TIRE IS BULGING AT CENTER OF TREED, CAUSING VEHICLE TO JUMP AND BOUNCE, CAUSING SPRING DAMAGE AND SEVERE VIBRATION OF VEHICLE AT HIGH SPEED..TIRE LOOKS AS IF IS GOING TO BLOW OUT..
Mileage: 150,000
WHEN I NORMAL DRIVE UNDER HOOD FIRE THE VEHICLE BURN OUT IF YOU NEED MORE FILE OR PICTURE I CAN SEND MAIL MY E MAIL ADDRESS (XXXX) PARTS OF THIS DOCUMENT HAVE BEEN REDACTED TO PROTECT PERSONALLY IDENTIFIABLE INFORMATION PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).
Mileage: 170,000
WHEN I NORMAL DRIVE UNDER HOOD FIRE THE VEHICLE BURN OUT IF YOU NEED MORE FILE OR PICTURE I CAN SEND MAIL MY E MAIL ADDRESS (XXXX) PARTS OF THIS DOCUMENT HAVE BEEN REDACTED TO PROTECT PERSONALLY IDENTIFIABLE INFORMATION PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).
Mileage: 170,000
WHEN I NORMAL DRIVE UNDER HOOD FIRE THE VEHICLE BURN OUT IF YOU NEED MORE FILE OR PICTURE I CAN SEND MAIL MY E MAIL ADDRESS (XXXX) PARTS OF THIS DOCUMENT HAVE BEEN REDACTED TO PROTECT PERSONALLY IDENTIFIABLE INFORMATION PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).
Mileage: 170,000
TL* THE CONTACT OWNS A 2005 CHEVROLET EXPRESS 3500 EQUIPPED WITH KENDA KLEVER TIRES, SIZE: LT225/75 R16. WHILE DRIVING AT APPROXIMATELY 65 MPH, THE REAR PASSENGER SIDE TIRE BLEW OUT. THE TIRE WAS REPLACED WITH A SPARE. THE CONTACT WAS A MECHANIC WHO DIAGNOSED THAT THE TREAD SEPARATED. THE TIRE WAS NOT REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE TIRE FAILURE MILEAGE WAS 6,000 AND THE VEHICLE FAILURE MILEAGE WAS 77,000. MA 10/5
Mileage: 77,000
PAINT PEEL ON ROOF, HOOD, DOORS. *TR
Mileage: 75,000
2005 CHEVROLET EXPRESS 3500. PARKING BRAKE CABLE ON REAR, DRIVERS SIDE, RUBBING AGAINST SIDE OF TIRE. TIRE RUBS DOWN UNTIL IT BREAKS. TIRE WAS TOTALLY SHREDDED BUT I WAS ABLE TO SLOW AND STEER TO SIDE OF ROAD. NEW TIRE PUT ON BUT THEY DID NOT SEE THE CABLE IN THE WAY OR RUBBING! I ONLY SAW IT BECAUSE I WAS LOOKING UNDER THE CAR FOR A NEW METALLIC CLANKING NOISE (THAT IS SOMETHING ELSE). MY NEW TIRE WAS ALMOST RUBBED THROUGH AFTER ONLY 3 WEEKS. I PULLED THE CABLE WAY BACK INTO ITS RETAINER BUT THE RETAINER IS ABOUT 1.5 SQUARE INCHES AND THE CABLE IS ONLY 1/8 IN SO IS NOT FIRMLY HELD IN PLACE (ONLY BY SOME FRICTION). IF YOU HAVE A CHEVY EXPRESS, CHECK YOUR CABLE AND TIRE. *TR
Mileage: 76,000
2005 CHEVROLET EXPRESS 3500. PARKING BRAKE CABLE ON REAR, DRIVERS SIDE, RUBBING AGAINST SIDE OF TIRE. TIRE RUBS DOWN UNTIL IT BREAKS. TIRE WAS TOTALLY SHREDDED BUT I WAS ABLE TO SLOW AND STEER TO SIDE OF ROAD. NEW TIRE PUT ON BUT THEY DID NOT SEE THE CABLE IN THE WAY OR RUBBING! I ONLY SAW IT BECAUSE I WAS LOOKING UNDER THE CAR FOR A NEW METALLIC CLANKING NOISE (THAT IS SOMETHING ELSE). MY NEW TIRE WAS ALMOST RUBBED THROUGH AFTER ONLY 3 WEEKS. I PULLED THE CABLE WAY BACK INTO ITS RETAINER BUT THE RETAINER IS ABOUT 1.5 SQUARE INCHES AND THE CABLE IS ONLY 1/8 IN SO IS NOT FIRMLY HELD IN PLACE (ONLY BY SOME FRICTION). IF YOU HAVE A CHEVY EXPRESS, CHECK YOUR CABLE AND TIRE. *TR
Mileage: 76,000
2005 CHEVROLET EXPRESS 3500. PARKING BRAKE CABLE ON REAR, DRIVERS SIDE, RUBBING AGAINST SIDE OF TIRE. TIRE RUBS DOWN UNTIL IT BREAKS. TIRE WAS TOTALLY SHREDDED BUT I WAS ABLE TO SLOW AND STEER TO SIDE OF ROAD. NEW TIRE PUT ON BUT THEY DID NOT SEE THE CABLE IN THE WAY OR RUBBING! I ONLY SAW IT BECAUSE I WAS LOOKING UNDER THE CAR FOR A NEW METALLIC CLANKING NOISE (THAT IS SOMETHING ELSE). MY NEW TIRE WAS ALMOST RUBBED THROUGH AFTER ONLY 3 WEEKS. I PULLED THE CABLE WAY BACK INTO ITS RETAINER BUT THE RETAINER IS ABOUT 1.5 SQUARE INCHES AND THE CABLE IS ONLY 1/8 IN SO IS NOT FIRMLY HELD IN PLACE (ONLY BY SOME FRICTION). IF YOU HAVE A CHEVY EXPRESS, CHECK YOUR CABLE AND TIRE. *TR
Mileage: 76,000
OUR SEAT BELTS WHEN HITTING MY BREAKS JUST UNLATCHED AND FELL APART ON THE DRIVER & PASSENGER SIDE. *JS
Mileage: 78,000
TL* THE CONTACT OWNS A 2005 CHEVROLET EXPRESS 3500. THE CONTACT STATED THAT THE SIDE DOOR HINGES WERE COLLECTING MOISTURE AND CAUSING THEM TO RUST, MAKING THE DOOR INOPERABLE. THE CONTACT CALLED THE MANUFACTURER REGARDING THE FAILURE AND THE MANUFACTURER ADVISED THAT THERE WERE NO RECALLS REGARDING THE DOOR HINGES. THE CONTACT STATED THE REAR SIDE DOOR DOES NOT OPEN AND COULD CAUSE A MAJOR SAFETY ISSUE. THE FAILURE MILEAGE AS 184,000.
Mileage: 184,000
2005 CHEVY EXPRESS VAN CAUGHT FIRE IN THE ENGINE COMPARTMENT, COMPLETE BURN. *TR
THIS IS A 29' MOTORHOME, WHEN TOWING IN HILLS/MOUNTAINS. GOING DOWN HILL ATTEMPTING TO SLOW DOWN THE VEHICLE, THE MOTORHOME STARTS SHAKING THROUGHOUT AND THE BRAKES BECOME ALMOST INEFFECTIVE. THE DEALERSHIP SERVICE DEPT INFORMED ME THE BRAKES ARE BARELY ADEQUATE TO STOP THE MOTORHOME WITHOUT A TRAILER. THE CHEVORLET G3500 HAS A TOWING RATINGS PER THE CHARTS OF 10000#. I WAS TOWING LESS THAN 5000#. *TR
Mileage: 9,800
OUR 2005 CHEVY EXPRESS 1 TON PASSENGER VAN BRAKES BY ITS SELF. IT HAS BEEN HAPPENING SINCE JULY 2009. WE TOOK IT TO A LOCAL MECHANIC AND HE REPLACED YAW SENSOR IT DID NOT STOP THE BRAKING. WE TOOK IT TO WHITE'S CHEVROLET DEALERSHIP IN CASPER WY AND THEY REPLACED F- MODULE IT DID NOTHING TO CHANGE THE PROBLEM. THE RIGHT FRONT BRAKE WOULD BRAKE AND THE THE TRACTION SYSTEM WILL KICK IN. WE TOOK IT BACK TO THE CHEVY DEALER AND THEY SAID THEY WOULD FIX IT. THE PERSON WE WERE DEALING WITH, BRIAN PARKS, CALLED AT ONE POINT AND SAID WE HAD A GHOST IN THE VAN. THEY HAD THE VAN FOR A LITTLE OVER A MONTH AND SAID THE TIRES WERE SLIGHTLY UNEVEN AND THAT MIGHT BE WHAT WAS CAUSING THE BRAKES TO ENGAGE BY THEMSELVES. THEY TOLD US THEY WOULD NO LONGER WORK ON IT AND TO COME AND GET IT. WE PICKED IT UP AND NOW THE LEFT FRONT BRAKE ENGAGES BY ITSELF SO HARD AT TIMES IT PULLS THE VAN TO THE LEFT. WE DON'T KNOW WHAT TO DO TO GET THIS PROBLEM SOLVED. THE VAN IS NOT SAFE ON ICEY ROADS OR DRY FOR
Mileage: 69,000
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.
Mileage: 165,000
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
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
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
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.
Mileage: 125
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.
Mileage: 125
Loss of motive power due to engine failure
Loss of Motive Power due to the Battery Energy Control Module
Electric Vehicle Battery Fires
Outboard Front Seat Belt Anchor Cable Failure
Fuel Line Leak
Data as of 2025. Sources: NHTSA Office of Defects Investigation (ODI) complaints database, NHTSA recall campaign API, NHTSA NCAP crash-test ratings, and NHTSA FARS for fatality cross-reference.
Read our methodology — how this data is sourced, computed, and verified.