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.

Flush brake fluid every 60,000 miles

Our technicians recommend flushing the brake fluid every 60,000 miles.  Brake fluid that is dirty may cause problems in the brake system.

Contamination of extended life coolant
Extended life coolant may become contaminated and require cooling system service before the recommended 100,000 miles.

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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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