Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2005 Chevrolet Silverado 2500 owners, lightly cleaned up (personal details are redacted by NHTSA).
Tl* the contact owned a 2005 Chevrolet Silverado 2500. When the air conditioner was activated, grey smoke emerged through the vents and flames suddenly appeared under the hood of the vehicle. The fire department was called and extinguished the fire, but the cause could not be determined. The vehicle was towed to a tow lot where it was deemed destroyed. There were no injuries sustained. The dealer and manufacturer were not informed of the failure. The failure mileage was 150,000.
The blower motor (for heat & air conditioning) stopped working and was replaced on our 2005 Chevy Silverado 2500. With in a year it stopped working again and upon inspection we along with raymond Chevrolet in antioch, illinois noticed that the blower motor was burned out and the resister harness was burnt. As if it was on fire. Thankfully no further damage was done besides the burning of the motor, wires and harness. This was replaced again on 10-30-08 and now on 06-23-09 again the motor has burnt out again. The dealership service department had no explanation why this has happened 3 times and being aware of this we make sure nothing is close to the dash preventing a spread of fire in case it were to happen again, which it has.
I purchased a "new" 2005 Chevy Silverado 2500 utility bed work truck...the dealership ripped me off with the trade in;refused to apply the cash back and down payment assistance GM was offering-and when I got the truck home,saw the inside of toolboxes were rusted...the heater blew,the airconditioning quit working,stereo/cd player quit,as well...the dealer refused to fix the rust;destroyed the pics and service report regarding the trust. The oil cap blows off...it's been replaced several times- and in jan 2009,truck kept overheating & brake lights went out...dealer could not find source of engine leak;and failed to fix brake lights,.they state it's not their problem. …
Tl* the contact owns a 2005 Chevrolet Silverado 2500. The contact stated that exhaust fumes were emitted from the vehicle in an unusual fashion and entered into the cabin of the vehicle. The vehicle was taken to an authorized dealer where the contact was informed that the engine manifold was warped because the bolts were corroded. The vehicle was repaired. The failure recurred approximately two years later. The vehicle was taken back to the dealer and was repaired a second time for the same failure. The manufacturer was made aware of the failure and offered no assistance. The failure mileage was 87,000. Updated 02/14/12 the consumer stated he corrected the problem by using stage 8 bolts and headers. Updated 03/16/12
The engine oil cooler lines and the transmission cooler lines leak at the crimp where the rubber hose and metal lines connect. After doing research online about this I have discovered it is a very common problem. Some people have replaced these lines multiple times only to have them leak a short while later. For those of us whose vehicles are out of warranty this can be very costly. I would also think that transmission fluid and motor oil contacting hot surfaces like an exhaust pose a fire hazard. At the very least the leaking oil is an environmental hazard. I have purchased oil cooler lines and am replacing them tomorrow but I am having trouble finding transmission lines.
2005 Chevy Silverado 2500 diesel truck on freeway on 01/25/2010 and the truck immediately lost power while pulling a trailer. Very dangerous. Consumer never made aware of tech bulletin or problem. TSB #05-06-04-047b injection harass. NHTSA #10017389. The truck has been taken to dealer for other recall notices and dealers never addressed the problem and should have before we were stuck out in the middle of the desert and had to get the vehicle and 5th wheel trailer towed. The consumers should be notified of this problem and Chevy dealers should fix problem with the injection harness because when a vehicle loses power on the freeway it is dangerous.
2005 Silverado pick up with 77000 miles pulling empty trailer( work) blows hole in #7 piston no warning, make it to nearest dealer takes them 2 weeks to decide engine ruined but not covered by warranty, they said by there ( general motors) paperwork it looks like I have a power adder( chip) that caused the problem( which I did not have). After obtained there ( TSB) information it states that only if there are multiple pistons damaged then there is a power adder, if only one is damaged it is a bad injector, they refused to pay and I could not afford to pay there $16000+ bill to put a new engine so took to independent shop and had another engine put in.
I took my 2005 Chevrolet Silverado pick up in for a exhaust leak. The manifold bolts rotted away. 3 bolts holding right and left exhaust manifolds in place. Vary very unsafe, one good bump in the road and it would drop. Vehicles with less than 30,000 miles have the same problem. GM knows about the problem and should have contacted it's customers. Vary dangerous. Fire, accident or exhaust fumes. Not good at all!!
Right side exhaust manifolds bolts rusted off causing exhaust gases to escape and causing check engine light to come on.cannot get the vehicle state inspected with the check engine light on. Mechanic says it needs to be repaired to get vehicle inspected.the others look like they May be failing also. This is a big out of pocket expense since it is no longer under warranty.
Exhaust manifold bolt head broke off. 1st bolt initially then second bolt next to it broke as well. No work has been done to motor or aftermarket parts added that would affect this part and create failure. Exhaust gas enters the underhood area sometime can be smelled inside cab. The exhaust makes a black plume up side of motor.
Engine complaints in other Silverado 2500 years
Frequently asked questions
How common are engine problems on the 2005 Chevrolet Silverado 2500?
NHTSA has 21 complaints about the engine & cooling of the 2005 Chevrolet Silverado 2500, 8% of the model year's 269 complaints. The component named most often is exhaust system (3 mentions).
Is there a recall for 2005 Chevrolet Silverado 2500 engine problems?
No. NHTSA lists no engine & cooling recall for the 2005 Chevrolet Silverado 2500. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2005 Chevrolet Silverado 2500 engine problems start?
Half of the complaints with a recorded mileage happened before about 77,000 miles, and 6% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 3 fires and 1 injury to engine & cooling problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.