2005 Chevrolet Express Owner Complaints

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 ID

11736689

Incident

May 4, 2026

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 ID

11730511

Incident

Apr 10, 2026

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 ID

11701219

Incident

Nov 23, 2025

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 ID

11487063

Incident

Sep 22, 2022

Mileage

200,000 mi

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 ID

11483591

Incident

Aug 1, 2022

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 ID

11421445

Incident

Jun 17, 2021

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 ID

11402633

Incident

Mar 5, 2021

Mileage

230,000 mi

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 ID

11184774

Incident

Mar 5, 2019

Mileage

36,400 mi

PAINT PEELING OFF, HAS BEEN FOR YEARS.

NHTSA ID

10808700

Incident

Jul 20, 2006

Mileage

23,000 mi

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 ID

10667416

Incident

Apr 15, 2014

Mileage

115,060 mi

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

NHTSA ID

10650140

Incident

May 15, 2013

Mileage

92,000 mi

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

NHTSA ID

10607157

Incident

Aug 15, 2013

Mileage

101,000 mi

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 ID

10605303

Incident

Jun 23, 2014

Mileage

82,868 mi

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 ID

10549184

Incident

Oct 1, 2013

Mileage

155,000 mi

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 ID

10465046

Incident

Jun 10, 2012

Mileage

130,000 mi

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 ID

10460964

Incident

Jun 7, 2012

Mileage

89,000 mi

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 ID

10444339

Incident

Jan 14, 2012

Mileage

70,000 mi

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 ID

10267068

Incident

Apr 24, 2009

Mileage

58,000 mi

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 ID

10212794

Incident

Jun 20, 2007

Mileage

2,700 mi

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 ID

10197741

Incident

Jun 20, 2007

Mileage

27,000 mi

PROBLEM WITH RECEIVING PROPER RECALL SCHEDULING**NAR**CC THE CONSUMER VEHICLE IS AN RV AND THERE IS NO FACILITY CLOSE ENOUGH THAT CAN ACCOMMODATE THE RV, THE NEAREST DEALER IS 5 HOURS AWAY. THE RECALL WAS REGARDING SEAT BELTS ON AN RV. *JB

NHTSA ID

10179562

Incident

Jan 1, 1901

SLIDING DOOR WAS CLOSING AT FIRST, THEN WHEN THE CHILD SAFETY LATCH WAS ENGAGED, IT WOULDN'T CLOSE. THEN WHEN WE SWITCHED THE LATCH BACK, THE DOOR CLOSED AND WOULDN'T OPEN AGAIN. THE DOOR, ALTHOUGH CLOSED MORE THAN BEFORE, WASN'T FULLY CLOSED AS IT KEPT THE DOME LIGHTS ON AND YOU COULD HEAR THE WIND BLOWING. THE FACT THAT THE DOOR WOULDN'T OPEN, WE HAD TO CLIMB IN AND OUT OF THE VAN VIA THE PASSENGER DOOR OR CLIMB OVER THE BACK SEATS AND OUT THE BACK DOORS. THE DOME LIGHTS HAD TO BE DISCONNECTED AS TO NOT RUN THE BATTERY DOWN OVERNIGHT. IT ALSO MADE DRIVING AT NIGHT DIFFICULT WITH THE LIGHTS ON. *NM

NHTSA ID

10140661

Incident

Oct 20, 2005

WHEN THE BRAKES WERE APPLIED THE VEHICLE SHIFTED INTO 3RD GEAR. THE VEHICLE WAS TAKEN TO THE DEALER, AND THEY COULD NOT FIND THE CAUSE OF THE PROBLEM. THIS HAPPENED NINE TIMES IN 2900 MILES. *AK *SC

NHTSA ID

10115397

Incident

Oct 26, 2004

Mileage

2,900 mi