Home › Chevrolet › Express Passenger › 2005
2005 Chevrolet Express Passenger: problems, recalls and fuel economy
Owners of the 2005 Express Passenger filed 59 complaints with NHTSA, led by brakes and body structure[1][2][3]. The EPA rates it at 14 to 15 MPG combined[4][5].
Most reported problems
NHTSA has 59 owner complaints on file for the 2005 Express Passenger[1]. Five mention a crash, four a fire and five an injury. No deaths are reported[1]. These are unverified owner reports, and one complaint can name several parts.
| Component group | Complaints | Median miles at failure |
|---|---|---|
| Brakes[2] | 13 | 55,900 |
| Structure[3] | 12 | 82,000 |
| Tires[7] | 7 | 76,000 |
| Seat belts[8] | 6 | not listed |
| Electrical system[9] | 6 | 101,000 |
| Suspension[10] | 5 | 45,000 |
| Power train[11] | 4 | not listed |
| Exterior lighting[12] | 4 | not listed |
Brakes. One of the 13 brake complaints involves a crash and one an injury[2]. In the sample of brake complaints we read, four describe a brake hose or line that rubbed against another part, wore through and leaked, which left the driver with little or no braking. Three more describe the ABS or traction system kicking in at the wrong time, or brakes applying or releasing on their own, even after a sensor or module was replaced[2].
Structure. In the structure sample we read, three texts describe door hinges that seized, rusted or snapped, and two describe paint peeling off. Two near-identical texts raise a steering idler arm concern[3]. The sample is small and a few texts look like repeats.
Tires. In the tire sample we read, three of seven describe a blowout, tread separation or sidewall split[7]. The owners name different tires and different mileages, so this is not tied to one cause.
Seat belts. Four of the six seat belt complaints we read describe buckles that would not release, jammed or came apart[8]. The same problem is the subject of recall 05V558, covered below[13].
Fires show up in a few groups: electrical (2), suspension (1) and power train (1)[9][10][11]. We have no complaint texts on those groups, so we cannot say what burned or why.
Recalls
NHTSA lists eight recalls for this model year[6], newest first.
- Wheelchair lift, Customizers (09V307). Dated July 2009, 3 vans with Ricon platform lifts[14]. The anti-stow interlock may not sense a person on the platform, so the lift could stow with someone still on it. The maker said it was working with Ricon to correct the lifts at no charge[14].
- Wheelchair lift, Main Mobility (09V272). Dated July 2009, 185 vans[15]. Same anti-stow problem. The remedy text says the lifts would be corrected at no charge, working with Ricon[15].
- Wheelchair lift threshold warning (09V270). Dated July 2009, 185 vans[16]. The threshold warning system may miss a person standing in a certain spot, so the lift could move under them. The remedy text says the lifts would be corrected at no charge, working with Ricon[16].
- Wheelchair lift threshold warning, Mobility (09V049). Dated February 2009, 86 vans[17]. Same threshold warning problem, with a correction at no charge worked out with Ricon[17].
- Wheelchair lift anti-stow, Mobility (09V050). Dated February 2009, 43 vans[18]. Same anti-stow problem, with a correction at no charge worked out with Ricon[18].
- Seat belt buckles (05V558). Dated December 2005, 425,593 vans[13]. Front and rear buckles may not latch or may not unlatch, so an occupant might not be held properly in a crash. Dealers inspect the buckles and replace the whole assembly if it does not work. If it works, they replace only the upper buckle cover. The recall ran in phases and the first mailing began in March 2006[13].
- Center brake lamp (05V530). Dated November 2005, 3 conversion vans[19]. The lens of the center high-mounted stop lamp lets too little light out, so drivers behind may not see the van braking. The fix is a new lamp assembly, which Santa Fe was arranging with Audiovox[19].
- Brake booster (05V043). Dated February 2005, 77,411 vehicles[20]. The accumulator on a Bosch hydro-boost brake booster may crack and separate. Fluid could leak, braking and steering would take more effort and a crash could happen without warning. Dealers test the unit and replace it free if it fails[20].
The five wheelchair lift recalls only matter if a van has a Ricon lift. The remedy text names the makers and their phone lines, but we cannot say whether a fix is available today. NHTSA's recall pages list the current status for each number.
Fuel economy
The EPA lists two engines for this model year[4][5][21].
| Engine and drive | City / highway / combined MPG | EPA annual fuel cost |
|---|---|---|
| 4.3L 6-cyl, 2WD[4] | 13 / 18 / 15 | $4,450 |
| 5.3L 8-cyl, 2WD[5] | 13 / 17 / 14 | $4,800 |
| 5.3L 8-cyl, AWD[21] | 13 / 17 / 14 | $4,800 |
All three use an automatic 4-speed and regular fuel. The annual cost uses EPA's current fuel price assumptions, not prices from when the van was new. The 6-cylinder is rated 1 MPG better combined than the 8-cylinder[4][5].
Safety ratings
NHTSA lists its 5-Star Safety Ratings for the 4 DR RWD version of this van as not rated[22]. That means we have no star score to compare.
Engine and size
The EPA data lists a 4.3L 6-cylinder and a 5.3L 8-cylinder[4][5]. Dimensions below are Canadian-market specifications and can differ slightly from US vans. They were converted from metric values.
| Variant | Length | Width | Height | Wheelbase | Curb weight |
|---|---|---|---|---|---|
| G1500[23] | 224 in | 80 in | 81 in | 135 in | 5,117 lb |
| G2500[24] | 224 in | 80 in | 81 in | 135 in | 5,789 lb |
| G2500 Extended[25] | 244 in | 80 in | 82 in | 155 in | 5,990 lb |
| G3500[26] | 224 in | 80 in | 81 in | 135 in | 5,930 lb |
| G3500 Extended[27] | 244 in | 80 in | 82 in | 155 in | 6,124 lb |
| H1500 AWD[28] | 224 in | 80 in | 81 in | 135 in | 5,593 lb |
The Extended versions are 20 inches longer in both body and wheelbase[25][27].
How 2005 compares with other years
Show the numbers
| Model year | Complaints | Recalls |
|---|---|---|
| 1996 | 19 | 2 |
| 1997 | 31 | 1 |
| 1998 | 29 | 1 |
| 1999 | 76 | 1 |
| 2000 | 96 | 1 |
| 2001 | 63 | 2 |
| 2002 | 70 | 0 |
| 2003 | 101 | 10 |
| 2004 | 57 | 7 |
| 2005 | 59 | 8 |
| 2006 | 45 | 17 |
| 2007 | 41 | 6 |
| 2008 | 41 | 11 |
| 2009 | 26 | 9 |
| 2010 | 30 | 6 |
| 2011 | 18 | 7 |
| 2012 | 20 | 6 |
| 2013 | 23 | 8 |
| 2014 | 25 | 8 |
| 2015 | 8 | 3 |
| 2016 | 15 | 6 |
| 2017 | 21 | 6 |
NHTSA counts complaints and recalls for each Express Passenger model year. The 2005 model year has 59 complaints and 8 recalls[6].
On complaints, five years are higher: 2003 (101), 2000 (96), 1999 (76), 2002 (70) and 2001 (63)[6]. That puts 2005 sixth highest among the 22 years listed[6]. On recalls, 2006 (17), 2008 (11), 2003 (10) and 2009 (9) have more[6]. The 2005 count of 8 is tied with 2013 and 2014[6].
These counts are not adjusted for how many vans were sold, so they show where reports landed, not how likely a problem is.
Should you buy a used 2005 Express Passenger?
A 2005 Express Passenger comes with a mixed record. Brakes and body structure draw the most complaints, and some of the brake complaints we read involve hoses wearing through[2][3]. Before buying, have someone check the brake lines and hoses, the door hinges and the tires. Ask whether the seat belt recall was done and whether the van has a wheelchair lift covered by the lift recalls[13][14]. The EPA rates it at 14 or 15 MPG combined, with an EPA annual fuel cost of $4,450 to $4,800[4][5], and we have no star safety rating for it[22].
Frequently asked questions
- What are the most common problems with the 2005 Chevrolet Express Passenger?
- Brakes (13 complaints) and structure (12) lead the 59 NHTSA complaints, followed by tires (7)[1][2][3][7]. In the samples we read, some brake complaints involve hoses wearing through[2].
- How many recalls does the 2005 Express Passenger have?
- NHTSA lists 8, covering wheelchair lifts, seat belt buckles, a brake lamp and a brake booster[14][15][16][17][18][13][19][20].
- What gas mileage does a 2005 Express Passenger get?
- The EPA lists 15 MPG combined for the 4.3L 6-cylinder and 14 MPG combined for the 5.3L 8-cylinder[4][5][21].
- Is the 2005 Express Passenger safe?
- NHTSA lists its 5-Star Safety Rating as not rated[22]. It has 8 recalls on file[6].
- Is 2005 a bad year for the Express Passenger?
- It has the sixth most complaints of the 22 years listed, 59 against a high of 101 in 2003[6].
Facts and sources
- NHTSA has 59 owner complaints on file for the 2005 Chevrolet Express Passenger (5 mention a crash, 4 a fire, 5 injuries, 0 deaths reported). NHTSA vehicle records
- 13 complaints name the brakes component group (1 crashes, 0 fires, 1 injuries, median mileage at failure 55,900). NHTSA vehicle records
- 12 complaints name the structure component group (0 crashes, 0 fires, 0 injuries, median mileage at failure 82,000). NHTSA vehicle records
- EPA rating for Express 1500/2500 2WD, 4.3L 6-cyl, Automatic 4-spd, Regular, Rear-Wheel Drive: 13 city / 18 highway / 15 combined MPG; EPA estimated annual fuel cost $4,450. EPA / DOE fueleconomy.gov
- EPA rating for Express 1500/2500 2WD, 5.3L 8-cyl, Automatic 4-spd, Regular, Rear-Wheel Drive: 13 city / 17 highway / 14 combined MPG; EPA estimated annual fuel cost $4,800. EPA / DOE fueleconomy.gov
- Owner complaints and recalls for every Chevrolet Express Passenger model year (chart above). NHTSA recall database
- 7 complaints name the tires component group (0 crashes, 0 fires, 0 injuries, median mileage at failure 76,000). NHTSA vehicle records
- 6 complaints name the seat belts component group (1 crashes, 0 fires, 3 injuries). NHTSA vehicle records
- 6 complaints name the electrical system component group (0 crashes, 2 fires, 0 injuries, median mileage at failure 101,000). NHTSA vehicle records
- 5 complaints name the suspension component group (1 crashes, 1 fires, 0 injuries, median mileage at failure 45,000). NHTSA vehicle records
- 4 complaints name the power train component group (1 crashes, 1 fires, 0 injuries). NHTSA vehicle records
- 4 complaints name the exterior lighting component group (0 crashes, 0 fires, 0 injuries). NHTSA vehicle records
- Recall 05V558, filed December 19, 2005: Seat Belts. NHTSA recall database
- Recall 09V307, filed July 29, 2009: Equipment Adaptive / Mobility. NHTSA recall database
- Recall 09V272, filed July 6, 2009: Equipment Adaptive / Mobility. NHTSA recall database
- Recall 09V270, filed July 6, 2009: Equipment Adaptive / Mobility. NHTSA recall database
- Recall 09V049, filed February 6, 2009: Equipment Adaptive / Mobility. NHTSA recall database
- Recall 09V050, filed February 6, 2009: Equipment Adaptive / Mobility. NHTSA recall database
- Recall 05V530, filed November 7, 2005: Exterior Lighting. NHTSA recall database
- Recall 05V043, filed February 8, 2005: Service Brakes, Hydraulic. NHTSA recall database
- EPA rating for Express 1500 AWD, 5.3L 8-cyl, Automatic 4-spd, Regular, 4-Wheel or All-Wheel Drive: 13 city / 17 highway / 14 combined MPG; EPA estimated annual fuel cost $4,800. EPA / DOE fueleconomy.gov
- NHTSA 5-Star Safety Ratings, 4 DR RWD: not rated. NHTSA vehicle records
- Transport Canada specifications via NHTSA vPIC, G1500 EXPRESS PASSENGER: length 224 in, width 80 in, height 81 in, wheelbase 135 in, curb weight 5,117 lb (converted from centimeters and kilograms). vpic.nhtsa.dot.gov
- Transport Canada specifications via NHTSA vPIC, G2500 EXPRESS PASSENGER: length 224 in, width 80 in, height 81 in, wheelbase 135 in, curb weight 5,789 lb (converted from centimeters and kilograms). vpic.nhtsa.dot.gov
- Transport Canada specifications via NHTSA vPIC, G2500 EXPRESS PASSENGER EXTENDED: length 244 in, width 80 in, height 82 in, wheelbase 155 in, curb weight 5,990 lb (converted from centimeters and kilograms). vpic.nhtsa.dot.gov
- Transport Canada specifications via NHTSA vPIC, G3500 EXPRESS PASSENGER: length 224 in, width 80 in, height 81 in, wheelbase 135 in, curb weight 5,930 lb (converted from centimeters and kilograms). vpic.nhtsa.dot.gov
- Transport Canada specifications via NHTSA vPIC, G3500 EXPRESS PASSENGER EXTENDED: length 244 in, width 80 in, height 82 in, wheelbase 155 in, curb weight 6,124 lb (converted from centimeters and kilograms). vpic.nhtsa.dot.gov
- Transport Canada specifications via NHTSA vPIC, H1500 EXPRESS PASSENGER VAN AWD: length 224 in, width 80 in, height 81 in, wheelbase 135 in, curb weight 5,593 lb (converted from centimeters and kilograms). vpic.nhtsa.dot.gov