2005 GMC Sierra 2500 Engine Problems

1). Dash light stays on constantly and reads SERVICE AIR BAG. This was checked out at an auto repair shop. If air bag doesn't respond, it could be fatal. 2). Check engine light is always on. Was checked out at an auto repair shop and repaired on 10/19/2021. 3). Right engine exhaust manifold is cracked and leaking exhaust. Was checked out at a muffler repair shop. In time I'm afraid fumes my leak into the truck cab. 4). A brake line ruptured and was repaired on 09/02/2020.

NHTSA ID

11561631

Incident

Sep 2, 2020

ALWAYS TURNS OFF WHILE DRIVING OR WHILE AT IDLE

NHTSA ID

11021058

Incident

Nov 1, 2015

Mileage

5 mi

2005 GMC 2500HD WITH 6.0 LITER GAS MOTOR. LEFT AND RIGHT BANK EXHAUST MANIFOLD TO ENGINE BOLTS BROKEN OFF IN HEAD. LEAKING EXHAUST FUMES AND CAUSING MY CHECK ENGINE LIGHT TO COME ON. GM NEED TO HAVE A RECALL ON THIS DUE TO THE NUMBER OF VEHICLES OUT THERE WITH THIS PROBLEM. THIS IS ALSO AN EMISSION PROBLEM DUE TO IT WILL CAUSE THE CAT CONVERTER TO OVERHEAT.. EPA? THANK YOU *TR

NHTSA ID

10536241

Incident

Aug 20, 2013

Mileage

85,123 mi

ALL EXHAUST MANIFOLD BOLTS ARE DEFECTIVE CAUSING THEM TO BREAK, WHEN THEY DO THE EXHAUST MANIFOLD SEPARATES FROM THE CYLINDER HEAD IN TURN DIRECTING ALL EMISSIONS FROM THE ENGINE INTO THE AIR, AND CABIN OF THE VEHICLE. THIS COULD CAUSE A FIRE IF NOT CORRECTED. ONE SPARK WOULD SET THE VEHICLE ON FIRE. *TR

NHTSA ID

10484109

Incident

Nov 13, 2012

Mileage

111,000 mi

EXHAUST MANIFOLD BOLTS ARE BREAKING OFF FOR NO APPARENT REASON. I HAVE FOUR BROKEN ALREADY AND AN EXHAUST LEAK DEVELOPING. THIS APPEARS TO BE A DEFECT IN MANUFACTURING. I HAVE A FRIEND WITH TWO OF THE SAME TRUCKS THAT THE SAME THING HAS HAPPENED TO. THERE ARE NUMEROUS COMPLAINTS POSTED ON THE WEB. I HAVE HAD MANY VEHICLES OVER THE YEARS AND WORKED THEM HARD BUT HAVE NEVER SEEN A BROKEN EXHAUST MANIFOLD BOLT ON ANY OF THEM. THIS CAN BE A DANGEROUS SITUATION AS HAVING EXHAUST LEAKS UNDER HOOD COULD CAUSE A FIRE. AS FAR AS I KNOW GM HAS NOT ISSUED A BULLETIN OR RECALL ON THIS BUT THERE SHOULD BE SOME REMEDIATION AS THIS IS AN EXPENSIVE REPAIR AND IT IS NOT A FAILURE CAUSED BY THE LACK OF MAINTENANCE. I HAVE ALSO HEARD REPORTS OF REPAIRED UNITS BREAKING AGAIN IN ABOUT THE SAME NUMBER OF MILES AND HAVING TO BE REPAIRED AGAIN. *TR

NHTSA ID

10482144

Incident

Feb 1, 2012

Mileage

35,000 mi

TL* THE CONTACT OWNS A 2005 GMC SIERRA 3500. THE CONTACT STATED THAT WHILE DRIVING 40 MPH, THE BRAKES WERE ENGAGED AND THE VEHICLE FAILED TO STOP. THE CONTACT MENTIONED THAT HE HAD TO ENGAGE THE EMERGENCY BRAKE IN ORDER FOR THE VEHICLE TO STOP. ALSO, THE CONTACT STATED THAT AFTER INSPECTING THE VEHICLE HE NOTICED OIL LEAKING. THE VEHICLE WAS NOT TAKEN TO THE DEALER. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE BRAKE LINES NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO DID NOT OFFER ANY ASSISTANCE. THE FAILURE AND CURRENT MILEAGE WAS 42,000. UPDATED 10/24/12 *CN UPDATED 11/08/12

NHTSA ID

10473726

Incident

Sep 2, 2012

Mileage

42,000 mi

BROKEN EXHAUST MANIFOLD BOLTS. FRONT AND REAR MANIFOLD BOLTS HAVE BROKEN ON BOTH THE PASSENGER AND DRIVER SIDES. AS A RESULT EXHAUST MANIFOLDS ARE NOW WARPING PUTTING UNDUE STRESS ON REMAINING MANIFOLD BOLTS AND CREATING AN EXHAUST LEAK. BOLTS ARE STEEL, MANIFOLDS ARE CAST, AND HEADS ARE ALUMINUM. DISSIMILAR METALS, HEAT, AND MOISTURE HAVE CAUSED THE BOLTS TO PREMATURELY RUST AND FAIL. EMISSIONS DILUTION WILL NOT ALLOW FOR A PASSING SMOG TEST IN 2013. GMC REFUSES TO ADDRESS THE ISSUE AT HAND, EVEN THOUGH THIS IS A RECURRING ISSUE ON ALL V8 ENGINES. ESTIMATE TO REPAIR; $2500. *TR

NHTSA ID

10443993

Incident

Nov 16, 2011

Mileage

94,500 mi

THIS MODEL YEAR HAS AN ENGINE DEFECT FROM THE MANUFACTURER. THE HEAD GASKET IS KNOWN TO BREAK CAUSING THE ENGINE TO OVERHEAT. THIS CAN CAUSE SEVERAL SAFETY ISSUES DEPENDENT ON THE CIRCUMSTANCE AT THE TIME OF THE ENGINE OVERHEATING. AFTER SOME RESEARCH, IT IS OPENLY KNOWN THAT THIS IS A DEFECT FROM THE MANUFACTURER FOR THIS PARTICULAR ENGINE YEAR.

NHTSA ID

10423588

Incident

Aug 19, 2011

Mileage

108,267 mi

MAJOR RUST OF THE UNDERCARRIAGE OF MY 2005 GMC SIERRA 78,000 MILES. SO FAR HAD TO REPLACE BRAKE ROTORS, BRAKE LINES , FUEL RADIATOR AND LINES. FRAME AND CROSS MEMBERS AS WELL AS CONTROL ARMS ARE ALL RUSTED. MADE COMPLAINT WITH GMC THEY HAD ME BRING TO A DEALER TO TELL ME THIS IS NORMAL RUSTING. TWO OF MY RELATIVES HAVE THE SAME YEAR TRUCK BUT ARE NOT EXPERIENCING THIS ISSUE AND WE ALL LIVE IN THE SAME AREA DRIVE SAME ROADS. *KB

NHTSA ID

10416571

Incident

Mar 16, 2011

Mileage

78,000 mi

THIS IS MY 2ND GMC 6.0L THAT HAS BROKEN EXHAUST BOLTS FIRST TRUCK BROKE 3 BOLTS AT 32,000 MILES, REPLACED BY DEALER AND BROKE BOLTS OFF AGAIN AT 39,000 MILES. NOW HAVE 2005 WITH 51,000 MILE WITH THREE BROKEN MANIFOLD BOLTS AND AN EXHAUST LEAK. THIS IS A VERY EXPENSIVE REPAIR THAT IS A DESIGN PROBLEM. *TR

NHTSA ID

10407412

Incident

Jun 15, 2005

Mileage

51,000 mi

EXHAUST MANIFOLD BOLTS BROKEN OFF (4). 6.0 L ENGINE AND EXHAUST IS ESCAPING AND ENTERING CABIN. *TR

NHTSA ID

10369228

Incident

Nov 15, 2010

EXHAUST LEAKING UNDER HOOD DUE TO BROKEN EXHAUST MANIFOLD BOLTS. CARBON MONOXIDE HAZARD. THIS SEEMS TO BE A COMMON PROBLEM FOR OWNERS OF SEVERAL YEARS OF GM ENGINES. *TR

NHTSA ID

10363033

Incident

Oct 30, 2010

Mileage

85,000 mi

2005 GMC 2500HD PICKUP TRUCK, HVAC BLOWER SPEED CONTROLLER/RELAY CONNECTOR GOT HOT, BURNED OUT CONNECTOR AND WIRE, LOTS OF SMOKE. IT HAPPENED WHEN TURN FAN TO HIGH. THE FAILURE WAS DUE TO CONTACT RESISTANCE AT THE CONNECTOR. THE WIRE HARNESS END IS TINTED COPPER, THE RELAY/CONTROLLER CONNECTOR IS BARE METAL. DUE TO GALVANIZATION OF DIFFERENT METAL IN THE CONNECTION SYSTEM, THE CONNECTOR IS UNDERSIZE FOR THE BLACK WIRE, WHICH IS THE RETURN CURRENT BECAUSE THE BLOWER ASSEMBLY IS PLASTIC. THE RESISTANCE BETWEEN THE CONTACT POINT OF THE CONNECTOR ACT AS HEATER AND GOT HOT, BURN OUT CONNECTION AND CONNECTOR HOUSING. THE SPEED CONTROL UNIT, WHICH COMPOSED OF FEW POWER RESISTOR IS MOUNTED IN THE AIR STREAM THAT IT WILL COLLECT VAPOR WATER DUE TO CONDENSATION WHEN AC IS IN USED. THIS CAUSE CORROSION IN THE SPEED CONTROLLER/RELAY BOARD. THE WORK AROUND IS BYPASS THE CONNECTOR BY SHORTING THE BLACK WIRE FROM THE BLOWER MOTOR TO THE BLACK INPUT WIRE THAT BURNED OUT. CUT THE INPUT BLACK WIRE, WIRE NUT IT TOGETHER WITH A 12 AWG JUMPER WIRE, CUT THE BLACK WIRE AT THE BLOWER MOTOR, WIRE NUT IT TO THE OTHER END OF THE JUMPER WIRE. AFTER THE JUMPER PUT IN, BLOWER FAN WORKS IN ALL SPEED AND NO SMOKE FROM CONNECTOR AND WIRE. *TR

NHTSA ID

10342860

Incident

Jul 9, 2010

Mileage

20,615 mi

THE EXHAUST MANIFOLD BOLTS WERE BROKE ON SIDE OF THE EXHAUST MANIFOLD SO FAR. THE MECHANIC AT FW TUCKER AND SON, IN, OSWEGO, NY 315-342-0444 STATED THAT THEY HAVE REPLACED THESE ON 12 TRUCKS AND AFTER FURTHER RESEARCH, I HAVE FOUND THAT THERE HAVE BEEN OVER 12,000 VEHICLES THAT HAVE TO HAD THESE REPLACED. THE TRUCK IS LESS THAN 5 YEARS OLD AND HAS 54,000 MILES ON IT. I CALLED AND FILED A COMPLAINT WITH GMC (SERVICE REQUEST #[XXX] ) AND WAS TOLD THAT THEY FOUND THAT IT WASN'T A COMMON PROBLEM AND THEY FOUND NO INDICATION THAT IT WAS AN ONGOING PROBLEM, HOWEVER 12,000 VEHICLES IS AN ONGOING PROBLEM. THE VEHICLE IS A 2005 GMC SIERRA 2500HD TRUCK. I HAD TO PAY TO HAVE THE EXHAUST MANIFOLD REMOVED, TO HAVE THE BOLTS EXTRACTED, THE COST OF THE NEW BOLTS AND THE INSTALLATION OF THE BOLTS, NEW EXHAUST MANIFOLD GASKETS AND SEALS. I ALSO HAD TO PAY TO HAVE THE ENGINE OIL REMOVED AND THE REPLACEMENT OF THE ENGINE OIL DIPSTICK TUBE. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

10329482

Incident

Apr 29, 2010

Mileage

54,465 mi

TICKING NOISE COMING FROM ENGINE COMPARTMENT. *TR

NHTSA ID

10257978

Incident

Jan 1, 2008

Mileage

50,000 mi

TL*THE CONTACT OWNS A 2005 GMC SIERRA 2500 HD. THE CONTACT STATED THAT WHEN HE DRIVES HIS VEHICLE UPHILL WITH A TRAILER IN TOW, THE VEHICLE SLAMS INTO THIRD GEAR, JERKS, AND OVERHEATS. THE FAILURE OCCURS AT VARIOUS SPEEDS. THE FAILURE MILEAGE WAS 35,000. UPDATED 5/13/08 *CN THE CONSUMER STATED SEVERAL DEALERS WERE TELLING HIM DIFFERENT THINGS AS TO WHAT WAS WRONG WITH THE VEHICLE. THE CONSUMER BELIEVED THERE IS A PROBLEM WITH THE ENGINE, TRANSMISSION AND TRANSFER CASE. ONE DEALER TOLD THE CONSUMER THE WRONG TRANSFER CASE WAS IN THE VEHICLE. A NEW SERPENTINE BELT WAS INSTALLED, THE FRONT DIFFERENTIAL WAS REPLACED, BECAUSE THE AXLE SHAFT WAS STUCK, THE AXLE SEAL WAS LEAKING AND BOTH HIGH PRESSURE LINES OF THE HYDROBOOST WERE LEAKING AS WELL. THE ENGINE LIGHT ILLUMINATED. THE CHARGE AIR COOLER WAS LEAKING RESIDUAL OIL FROM THE LOWER RIGHT CORNER. UPDATED 05/13/08.

NHTSA ID

10225718

Incident

Jul 1, 2006

Mileage

35,000 mi

WHEN CLIMBING A SIGNIFICANT GRADE , 6%, WHILE TOWING 12.500# 5TH WHEEL ON A DAY WITH HIGH AMBIENT TEMPERATURE , 95% ENGINE TEMPERATURE, IMMEDIATELY BEGAN TO CLIMB AND REACHED ALMOST OVERHEAT WHEN I FORTUNATELY FOUND A PLACE TO PULL OFF THE ROAD. INCIDENT TOOK PLACE ON THE GRAPEVINE IN CA. IF I HADN'T BEEN ABLE TO PULL OVER I WOULD HAVE BEEN STUCK IN TRAFFIC LANE WITH 18 WHEELERS RIGHT BEHIND ME. 2 DEALERS WERE UNABLE TO HELP.*AK

NHTSA ID

10187387

Incident

Jul 30, 2006

Mileage

12,000 mi

WHILE TRAVELING WEST OF DENVER, COLORADO MY 2005 GMC SIERRA 2500HD EQUIPPED WITH THE DURAMAX DIESEL OVERHEATED TO THE POINT OF THE VEHICLE SHUTTING DOWN. THIS HAPPENED ON A STRETCH OF HIGHWAY WHERE THERE WAS NO SHOULDER TO PULL OFF ON RESULTING IN AN EXTREMELY HAZARDOUS CONDITION. I HAVE DONE EXTENSIVE ON-LINE RESEARCH AND HAVE FOUND THIS TO BE A COMMON OCCURRENCE WITH THE 2004.5 AND 2005 MODEL YEAR CHEVROLET AND GMC HD SERIES TRUCKS EQUIPPED WITH THE DIESEL MOTOR. NUMEROUS PEOPLE HAVE TAKEN THEIR TRUCKS TO LOCAL CHEVROLET AND GMC DEALERSHIPS BUT GM HAS BEEN UNABLE OR UNWILLING TO HELP THUS FAR. THESE TRUCKS ARE CREATING DANGEROUS SITUATIONS THAT I FEAR WILL RESULT IN SERIOUS INJURY OR DEATH. *JB

NHTSA ID

10137610

Incident

Sep 15, 2005

Mileage

9,900 mi