Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety.

Print this page Notes: It didn't take long for the cladding to fade, discolor, and in some cases crack. Cladding is the protective plastic piece that runs along the outside of vehicles, and exposure to both heat and UV rays give the Avalanche's cladding a chalky, faded appearance.

Owners have said the problem is especially bad on the panels near the cargo bed. Eventually, GM agreed to a one-time treatment of ArmorDillo, a protective treatment similar to what you find in any auto shop. Unfortunately, that would only help for 6 months (on average).

Eventually, GM offered another coating solution for owners within the 3 year / 36,000 mile original warranty under TSB:04-08-111-001C.


hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
112,276 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2005 Chevrolet Avalanche fuel system problems

fuel system problem

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2005 Chevrolet Avalanche Owner Comments

problem #11

Dec 072015


  • 215,000 miles


The fuel lines rubbing together causing fuel to dump every where right next to the cat on the driver side of the truck N this is not a recall. Then I say its attepmed murder charge agaisnt Chevy....

- Lyndhurst, NJ, USA

problem #10

Apr 172015


  • 111,836 miles
The defective fuel lines rubbed together and caused a leak. I paid a local dealership about $1100 dollars to replace the fuel lines as it was unsafe. My vehicle is not under a recall but in researching, it was discovered that others have a recall. I opened an incident with Chevrolet as a defect but they were not able to assist as my truck is over 70K miles and pasted the warranty, the fuel lines are next to the catalytic converter and would have caused a fire.

- Castle Rock, CO, USA

problem #9

Mar 112015

Avalanche 4WD 8-cyl

  • 110,600 miles
After driving the smell of fuel comes from the engine by the drivers door. I contacted GM and my vehicle does not show on the list of this known recall. They passed me to a local dealership which stated my vehicle is not one that falls under the recall and admitted they had fixed others with similar issues. This is appalling that a manufacture can assist some customers but not all. I will never purchase another GM vehicle again.

- Castle Rock, CO, USA

problem #8

Mar 032014

Avalanche 8-cyl

  • 105,000 miles


Gas was dripping out of one of lines, after smelling gasoline for a month or so. Today the truck will not start and I'm afraid to jump start it.

- Brookfield, MA, USA

problem #7

Oct 082013

Avalanche 8-cyl

  • 106,226 miles
Vehicle running fine and no warning lights - noticed fuel smell in garage and took in for oil change and see what's up - found the entire top of the fuel tank was a puddle of fuel and was running down sides. Had the tank dropped and found the top of the fuel pump was rotted away where the pressure and return lines exit pump and before they attach to the plastic fuel lines. Only leaks when vehicle running so had no spots in garage but was leaking alot while driving - 25 mile drive to shop used 7 gallons of fuel.

- Perry, OH, USA

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problem #6

Sep 132013

Avalanche 8-cyl

  • 127,000 miles
I noticed a strong smell of gasoline and upon inspection found a significant fuel leak under the driver's door. A closer look reveals that there are 2 rubber fuel lines that touch and have worn through each other, causing them to leak fuel. This is all within inches of the exhaust system. Any reasonable person would assume that this is a fire hazard! this is an obvious design flaw that could easily be avoided.

- Prairie Du Chien, WI, USA

problem #5

Apr 042013

Avalanche 8-cyl

  • 81,194 miles


Driving home from work, I notice a raw gas smell. Pulled into my driveway, left the truck running and got out to see what was going on. Looked under the vehicle and saw gas pouring out. Stopped the engine and got under the truck for a closer look. Upon inspection, I noticed that the two plastic braid over rubber fuel lines were coiled over each other causing them to rub, wear away the plastic braid and rub the rubber hose to the point of creating a hole. This is where the gas was spraying out from, right neat to the exhaust pipe! I immediately got out from under the truck for fear that it might ignite. Looked on-line and saw multiple complaints exactly what I found on my inspection!

- Litchfield, NH, USA

problem #4

Feb 282013

Avalanche 8-cyl

  • 75,370 miles
The contact owns a 2005 Chevrolet Avalanche. The contact stated that vehicle smelled of fuel. The vehicle was taken to the dealer and it was determined that the fuel pump module and the fuel feed pressure line had to be replaced because of rust. The technician also stated that the lines were exposed and the road salt caused the lines to rust. The failure and current mileages were 75,370.

- Windham, OH, USA

problem #3

Jul 262012


  • 86,000 miles
The contact owns a 2005 Chevrolet Avalanche. The contact stated that while refueling, the fuel that was being pumped into the vehicle began pouring out. The vehicle was towed to the dealer for diagnosis where the fuel pump was replaced. The contact attempted to refuel the vehicle and fuel spewed out from the filler neck, saturating the contact with gasoline. The vehicle was returned to the dealer where she was informed that the vehicle needed a new canister and sensor. The vehicle was repaired. The failure mileage was 86,000 and the current mileages was 90,000.

- Scotsdale, AZ, USA

problem #2

Sep 072012


  • 110,000 miles
Noticed a strong gas odor in the garage. I couldn't see any leakage until I started (pressurized the fuel lines). I noticed a braided area of the fuel lines that cross over each other, touching, which caused them to rub together creating a pin hole in each line. When pressurized, they shoot fuel out. Luckily, they didn't cause a fire as we had just finished a 700 mile trip with our grand kids. The shop wants $805 to replace the lines. This is a safety hazard that should be recalled. Very dangerous!!!

- Meridian, ID, USA

problem #1

Jul 132012

Avalanche 8-cyl

  • 106,808 miles
Arrived at work this morning and my 2005 Chevy Avalanche was leaking fuel, upon further inspection the fuel lines were rubbing together and caused a break in the line.

- Fountain, CO, USA

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