Which parts fail
Components named in complaints (battery, alternator, wiring, ignition, instrument cluster, infotainment).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2005 GMC Sierra 2500 owners, lightly cleaned up (personal details are redacted by NHTSA).
1). Dash light stays on constantly and reads SERVICE AIR BAG. This was checked out at an auto repair shop. If air bag doesn't respond, it could be fatal. 2). Check engine light is always on. Was checked out at an auto repair shop and repaired on 10/19/2021. 3). Right engine exhaust manifold is cracked and leaking exhaust. Was checked out at a muffler repair shop. In time I'm afraid fumes my leak into the truck cab. 4). A brake line ruptured and was repaired on 09/02/2020.
After returning from a day of shopping, I parked my truck at the back, like always. I had been noticing oil spots for the last few days but chalked it up to age and mileage of the truck. After about two hours I saw smoke from the back area where I parked. I ran outside to catch to my surprise! My truck was on fire, I as quickly as possible, grabbed the garden hose and put out the fire! I realized as I looked, that the fire had started at the area under the hood where the fuses, and wiring were located. As I slowly rebuilt my truck, I realized that the fire was not the only problem that I had! The fact of the matter was that if the fire had not shut my truck down, there were a whole array of other problems that I would of had to repair.
Tl* the contact owns a 2005 GMC Sierra. The contact stated that while the vehicle was parked and turned off the fog lamps activated independently. While inspecting the vehicle it was discovered that the driver side dashboard had melted and a burning odor was present inside the cabin of the vehicle. The fire department was not notified. The cause of the failure was not yet determined. The manufacturer and local dealer was not notified. The failure mileage was 160,000.
Today when I parked my GMC Sierra 2500hd, I turned off the key switch and I noticed my blower motor was still running. After a short period of time I smelt something burning. I went out underneath the hood of my vehicle located the fuse box and removed the 40 amp blower motor fuse and that shut down the heater and the smell starting going away. It was 19 degrees here in oklahoma at the time of incident. I did some research on the internet and got several hits about GMC trucks that experienced the same issue except some of the vehicles burned completely to the ground. I also got information from the internet that general motors of Canada recalled all there GM products that had the same blower motor assembly. I filed a complaint with general motors, detroit. They said they had no recalls.
Replaced every module in the heater system in my 05 GMC Sierra several times, and so has just about everyone else I know who owns one. Now my wiring harness burned without blowing any fuses. GM should have a recall on this, and find the problems, and fix them, before everyone who owns one goes broke repairing them.
Tl* the contact 2005 GMC Sierra 2500 hd. The contact stated after parking the vehicle, the fan motor relay wires burned. The failure was not diagnosed by the dealer or a local mechanic. The manufacturer was notified. The approximate failure mileage was 170,000.
Wiring harness from blower motor to resistor pack located in the heater coil area under the dash on the passenger side of vehicle. This was repaired by the dealer once or twice before as far as we can see.
2005 GMC 2500hd pickup truck, HVAC blower speed controller/relay connector got hot, burned out connector and wire, lots of smoke. It happened when turn fan to high. The failure was due to contact resistance at the connector. The wire harness end is tinted copper, the relay/controller connector is bare metal. Due to galvanization of different metal in the connection system, the connector is undersize for the black wire, which is the return current because the blower assembly is plastic. The resistance between the contact point of the connector act as heater and got hot, burn out connection and connector housing. The speed control unit, which composed of few power resistor is mounted in the air stream that it will collect vapor water due to condensation when ac is in used. This cause corrosion in the speed controller/relay board. …
1) the driver door power windows,locks,and extended mirror buttons quit working,I can be driving down the road and I cant roll the windows down ,cant adjust my mirror and time that I stop to check the fuzes the door controls start working again. I try to lock the doors when I get out of the truck and nothing is working the pass.side works fine,I took off the door panel and they start working but by the time I put the panel back on .there still work but come back out and they quit again. 2)something wrong with my steering I thought it was my powersteering pump and replaced it ,but there still something wrong I think it might be the steering box I have oil leaking somewhere around there 3)its my air conditioner and heater, I can have the air on I get nothing but hot air on the driver side and cold on the pass side.I can use the vent with air and its the same,just hot on the driver …
I bought my GMC Sierra 2500 in June of 2005. Shortly after I bought the truck I started to notice rust on the trailer hitch and frame rails. As the years have gone by, the entire undercarriage is rusted over. Over the last several years a brake line rusted through and the brake pads & rotors have been replaced several times. I was lucky to be picking my truck up from the shop after an oil change & not driving it, when I noticed brake fluid on the ground under my truck.my speedometer does not work properly & the dashboard lighting works occasionally. My trailer hitch rusted so bad that the last time I put the receiver into the hitch it was stuck & I had to get a friend to connect a chain to his truck & while I drove forward & he reversed, the receiver finally broke free after approx. 10 minutes.
Electrical complaints in other Sierra 2500 years
Frequently asked questions
How common are electrical problems on the 2005 GMC Sierra 2500?
NHTSA has 42 complaints about the electrical system of the 2005 GMC Sierra 2500, 37% of the model year's 115 complaints. The component named most often is instrument cluster/panel (11 mentions).
Is there a recall for 2005 GMC Sierra 2500 electrical problems?
No. NHTSA lists no electrical system recall for the 2005 GMC Sierra 2500, though it has 1 recall for other components. 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 GMC Sierra 2500 electrical problems start?
Half of the complaints with a recorded mileage happened before about 70,000 miles, and 8% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 5 fires and 0 injuries to electrical 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.