2005 Chevrolet Express 2500 Repair and Maintenance

A guide to problems, costs, maintenance and repair for your 2005 Chevrolet Express 2500

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2005 Chevrolet Express 2500 Problems

Erratic Fuel Gauge Operation

It is common for the fuel level sensor in the fuel tank read the fuel level incorrectly. The sensor must be replaced to correct the condition. Our technicians recommend having the complete fuel pump module replaced on high mileage vehicles.

One or More Rear Lights May Not Work

The tail light wiring harness in the cargo area is not protected very well. As a result it may become damaged due to normal wear a tear. This damage can causing some or all of the rear lights to stop working.

Electrical components under front carpet may be damaged when cleaning van interior
Various electrical components under the front carpet/rubber mat may become damaged if excess water is used to clean the rear cargo area.

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2005 Chevrolet Express 2500 Questions

How do you air test the problem (1 answer)

Need to know how to air test the problem

How do fix the problem of oil in radiator (1 answer)

Once we are sure that the problem of oil in the radiator is what we think which is intake gasket how do we fix it

Could the oil in the radiator be from a intake manifold gasket? (1 answer)

I have heard that it could be the intake manifold gasket

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2005 Chevrolet Express 2500 Recalls

Seat Belts May Not Latch or Unlatch

On certain vans, the front and rear seat belts will not latch or unlatch. In a crash, the risk of injury is increased if the seat occupant is not properly restrained. Dealers will inspect the seat belt buckles, and will replace the buckle assembly if the buckle is found to be inoperative. If the buckle is found to function, only the upper buckle cover will be replaced. The recall began March 15, 2006. The GM recall number is 05113.

Hydraulic Brake Booster May Fail

On vehicles equipped with the Bosch hydraulic brake booster, the boost pressure accumulator may crack and break away from the hydro-boost assembly during normal operation. If this were to happen while the hood is open, fragments from the accumulator could injure people standing in the immediate area. The loss of fluid while driving would cause increased steering and braking effort and a crash could occur without warning. Dealers will test the hydro-boost assembly for function of the two-function valve. If the hydro-boost assembly fails the test, it will be replaced free of charge. The recall began March 23, 2005. The GM recall number is 05006.

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