Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
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).
I got into an accident with my 2005 chevy silverado by rear ending some one at a stop sign. I pulled up behind the vehicle and stopped to wait for them to go the it was my turn she didn't look well enough and had to hit her breaks again and so then did I but my truck did not stop in time because the breaking system delayed
October 29,2020 I was traveling down a highway when I noticed traffic was stopped and when I went to apply my brakes the pedal went all the way to the floor and I had nothing not even a light came on to notify my of an issue. I also tried to apply the emergency brake and it snapped and at that point I had to leave the road way to avoid hitting any cars or anyone, and in doing so iwent towards a ditch and ramped a driveway. We have ;looked into the recalls and its the same parts we are having trouble with on this truck and why it caused me to wreck. Hydro boost system, and the emergency brake system. The codes that I pulled from the NHTSA. These all are whats has happened with my vehicle. …
Fuel fitting break and leak fuel everywhere I have had two of these trucks that have done this and it has made my animals sick
Brake lines rusted out prematurely and burst, causing loss of braking ability. Had to replace every brake line on the entire truck, for they were all extremely rusty. 2 months later my fuel line also sprung a leak due to excessive rust, causing fuel to spill, check engine lights, and hard starting. Both of these issues present major safety concerns, and unfortunately are extremely common with these trucks.
The steel fuel lines and steel brake lines are corroding and leaking. On October 8th 2015 my truck begain to leak diesel fuel from the rusted fuel lines. While fixing the fuel leak the technician also notices that the brake lines were also starting to rust and will need to be replaces soon before they fail.
During a routine morning commute, I noticed the check engine light had illuminated. Immediately following the malfunction, I noticed a severe decrease in engine power and the engine started to vibrate and mis-fire heavily. I was in heavy traffic and had to pull off of the road to avoid a potential accident situation. I then shut the truck off, and re-started the vehicle to possibly re-set the light. The engine started and seemed to run smoothly again, but the light stayed illuminated. It was 7 am, so I decided to very slowly drive to the dealership where I had purchased the truck. The technician performed a diagnosis, and found a hard code of p2146 insulate ficm. I was then told that the main fuel injector system wiring harness had chaffed on a factory installed bracket and that it would need to be replaced. …
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. …
While driving along on a mountain road, the check engine light came on and I suddenly lost power to maintain speed. The truck went into what is commonly called "limp mode", unable to make any more than 10 MPH. I discovered that a problem common to this make model year occurred. The wiring harness to the fuel injjector (diesel) shorted to injector #2 and #7. The computer shut down the fuel to that cylinder bank as a result of the short. This is commonly spoken of in internet blogs and GM has a TSB for a repair. It is TSB 05-06-04 047b (I believe). It calls for replacing the wiring harness as it has become worn due to improper engineering and placement. The parts have been updated to prevent this. It costs $576.00 to repair. I believe this should require a recall. What would have happened to me had this occurred on a highway at highway speed. …
I have a 2005 Chevy Silverado with a 8.1 liter engine, I was turned down on my warranty because there was rust in the fuel rail. We took fuel samples and there was no water in the fuel tank, nor the fuel lines. So how did the rust get in the fuel rail and injectors. I did notice that the new rail that the GM dealer installed was stainless steel. When I bring it up the dealer nor GM will talk about it. This repair was going to be warranty but instead it cost me $1,145.50 dollars. This was the second time I took it in to the dealer. The people I bought the truck from said they would give me my money back, but now all their offering me is $218.00 I told them to shove it. This truck costs me $41,900.00 dollars! The last thing I want is this warranty company to tell me is no! The warranty cost me another 2,000.00 I can tell it isn't worth the paper it is written on. …
On January 23, 2009, the #7 injector harness shorted and had to be replaced. On March 21, 2009, the ses light came on and the truck sounded different running, but did not lose power. Diagnostics showed problems with the fuel injector module. On March 22, 2009, the ses light came on and the truck started running rough and lost engine power (just like it did on January 23). The truck had to be towed to the Chevrolet dealership again. This time the #2 fuel injector harness had shorted and had to be replaced. With both incidents, the fuel injector harnesses were replaced with a new harness that has a 90 degree plug and longer wires. This is not covered by warranty and costs $400+ to replace each one. Within 2 months and 2500 miles both the #2 and #7 fuel injector harnesses have shorted and had to be replaced.
Fuel System complaints in other Silverado 2500 years
Frequently asked questions
How common are fuel system problems on the 2005 Chevrolet Silverado 2500?
NHTSA has 24 complaints about the fuel & propulsion system of the 2005 Chevrolet Silverado 2500, 9% of the model year's 269 complaints. The component named most often is fuel injection system (2 mentions).
Is there a recall for 2005 Chevrolet Silverado 2500 fuel system problems?
No. NHTSA lists no fuel & propulsion system 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 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 74,000 miles, and 18% before 25,000 miles.
Is it dangerous?
Owners linked 2 crashes, 1 fire and 0 injuries to fuel & propulsion system 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.