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.

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Print this page Notes: The Chevy Express is mechanically identical to the GMC Savana.


hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
47,520 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 Express brakes problems

brakes problem

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2005 Chevrolet Express Owner Comments

problem #5

Oct 022010

Express 6-cyl

  • 53,800 miles


I own a 2005 Chevrolet Express 1500 V6 and while driving to my house from work I lost all brakes due to a brake line failure, the two hydraulic brake hoses that are attached to the master cylinder are in contact with another metallic brake hose under them, by rubbing together for four years caused the hoses to wear and rupture and nearly caused a crash.

- Kearny, NJ, USA

problem #4

Aug 102009


  • 9,800 miles
This is a 29' motorhome, when towing in hills/mountains. Going down hill attempting to slow down the vehicle, the motorhome starts shaking throughout and the brakes become almost ineffective. The dealership service dept informed me the brakes are barely adequate to stop the motorhome without a trailer. The chevorlet G3500 has a towing ratings per the charts of 10000#. I was towing less than 5000#.

- Wasilla, AK, USA

problem #3

Jul 012009


  • 69,000 miles
Our 2005 Chevy express 1 ton passenger van brakes by its self. It has been happening since July 2009. We took it to a local mechanic and he replaced yaw sensor it did not stop the braking. We took it to white's Chevrolet dealership in casper wy and they replaced F- module it did nothing to change the problem. The right front brake would brake and the the traction system will kick in. We took it back to the Chevy dealer and they said they would fix it. The person we were dealing with, brian parks, called at one point and said we had a ghost in the van. They had the van for a little over a month and said the tires were slightly uneven and that might be what was causing the brakes to engage by themselves. They told us they would no longer work on it and to come and get it. We picked it up and now the left front brake engages by itself so hard at times it pulls the van to the left. We don't know what to do to get this problem solved. The van is not safe on icey roads or dry for that matter. When the brake starts engaging the traction control comes on and the brake will no longer engage.

- Kaycee, WY, USA

problem #2

Apr 242009


  • 58,000 miles
The contact owns a 2005 Chevrolet Express cut-away G3500. When the contact depressed the brake pedal at 10 mph, the vehicle became difficult to stop. Upon further inspection, he noticed brake fluid leaking from the hoses. He took the vehicle to a local repair shop and the mechanic stated that the brake lines were rubbing together, which caused the hose to rupture. The contact is in the process of having the vehicle repaired. The failure and current mileages were 58,000.

- Gettysburg, PA, USA

problem #1

Mar 152009


  • 47,000 miles
1) total brake failure while driving 2) both brake lines ruptured at flexible section below master cylinder. 3) replaced all brake lines, refilled system and bled system.

- South Plainfield, NJ, USA

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