2005 Chevrolet Kodiak problems

General information about Chevrolet-Kodiak
Overview of popular issues
Analysis of common problems
Сomplaints list
Recalls list

The Chevrolet Kodiak and GMC TopKick are a range of medium-duty trucks that were produced by the Chevrolet and GMC divisions of General Motors from 1980 to 2009. Introduced as a variant of the medium-duty C/K truck line, three generations were produced. Slotted between the C/K trucks and the GMC Brigadier Class 8 conventional, the Kodiak/TopKick were developed as a basis for vocationally oriented trucks, including cargo haulers, dump trucks, and similar vehicles; on later generations, both cutaway and cowled-chassis variants were produced for bus use.

Following years of declining market share, General Motors (in line with Ford Motor Company) sought to exit heavy-truck manufacturing. After struggling to enter joint ventures or sell the rights to its product line, the company ended production of the Kodiak and TopKick in 2009. The final medium-duty truck, a GMC TopKick 5500, rolled out of Flint Truck Assembly on July 31, 2009.

For the 2019 model year, after a ten-year hiatus, General Motors re-entered the conventional medium-duty truck segment. Developed in a joint venture with Navistar International, the Chevrolet Silverado 4500/5500 is a Class 4–6 vehicle. Slightly smaller than the Kodiak/Topkick, the Silverado 4500/5500 is marketed exclusively as a Chevrolet (with no GMC counterpart).

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Common 2005 Chevrolet Kodiak problems

Based on complaints from owners, common problems with the Chevrolet Kodiak 2005 include steering issues, power steering failure, and high repair costs. The 2005 Chevrolet Kodiak has been associated with the most overall complaints, particularly related to steering problems. One of the most reported problems is power steering failure, which can be costly to fix, with an average repair cost of $1,000 and occurring at around 61,000 miles.

Power steering failure in the 2005 Chevrolet Kodiak can lead to difficulties in steering the vehicle, making it unsafe to drive. This issue can manifest as stiff or unresponsive steering, making it challenging to maneuver the vehicle effectively. The power steering system is crucial for assisting the driver in steering the vehicle with ease, and any failure in this system can compromise the safety and drivability of the car.

Owners of the 2005 Chevrolet Kodiak have reported experiencing power steering failure, which can be a significant safety concern. When the power steering system fails, it can result in increased steering effort, making it challenging to control the vehicle, especially at lower speeds or when parking. This issue can pose a risk to both the driver and other road users, highlighting the importance of addressing power steering problems promptly to ensure safe operation of the vehicle.

In summary, the 2005 Chevrolet Kodiak has been associated with steering problems, particularly power steering failure, which can lead to safety hazards and costly repairs. Addressing these issues promptly and ensuring regular maintenance can help mitigate the risks associated with steering problems in this vehicle.

What is the fuel mileage for a 2005 Chevy Kodiak?

Based on data from 6 vehicles, 297 fuel-ups and 83,372 miles of driving, the 2005 Chevrolet C5500 Kodiak gets a combined Avg MPG of 8.17 with a 0.20 MPG margin of error.

Why did Chevy stop making the Kodiak?

What motor is in the 2005 Chevy Kodiak?

6.6L V-8 Duramax diesel

It is powered by a 6.6L V-8 Duramax diesel that is mated to an Allison 1000 five-speed automatic and produces 300 hp and 520 lb-ft of torque.

What engine is in the Kodiak?

ENGINE

Engine Type	686cc liquid-cooled SOHC 4-stroke
Fuel Delivery	Yamaha Fuel Injection (YFI), 44mm
Transmission	Ultramatic V-belt with all-wheel engine braking; H, L, N, R, P
Final Drive	Lever-operated 2WD/4WD; shaft
Fuel Capacity	4.8 gal

2005 Chevrolet Kodiak car problems categorized by type of issue

After analyzing all complaints sent to the NHTSA and researching popular Chevrolet Kodiak problems, we found that the most common problems with these 2023 model year vehicles are:

Service brakes problems
Vehicle speed control problems
Hydraulic problems
Fuel system problems
Other problems

The graph below shows statistics for all 2005 Chevrolet Kodiak vehicle components and the number of complaints received.

2005 Chevrolet Kodiak complaints

The NHTSA has received 3 complaints about various vehicle components related to the 2005 Chevrolet Kodiak.

2014-04-01

SERVICE BRAKES PROBLEM

Date Of Incident: 2007-04-17
VIN: 1GBE4C3235F
Components: SERVICE BRAKES
Summary: TL* THE CONTACT OWNS A 2005 CHEVROLET KODIAK. THE CONTACT STATED THAT THE EMERGENCY BRAKE FAILED TO LOCK WHEN ENGAGED. THE CONTACT ALSO MENTIONED THAT THE EMERGENCY BRAKE WOULD RELEASE INDEPENDENTLY. THE VEHICLE WAS NOT TAKEN TO THE DEALER. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 5,000 AND THE CURRENT MILEAGE WAS 38,000. UPDATED 5/27/14*CN

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2009-01-14

SERVICE BRAKES, HYDRAULIC,FUEL SYSTEM, OTHER,VEHICLE SPEED CONTROL PROBLEM

Date Of Incident: 2008-05-01
VIN: 1GBE4C1225F
Components: SERVICE BRAKES, HYDRAULIC,FUEL SYSTEM, OTHER,VEHICLE SPEED CONTROL
Summary: TL*THE CONTACT OWNS A 2005 CHEVROLET KODIAK. THE CONTACT HAS BEEN EXPERIENCING ISSUES WITH THE EXHAUST BRAKES ON HIS VEHICLE. THE BRAKES HAVE BEEN REPLACED NUMEROUS TIMES OVER THE YEARS, BUT THE FAILURE PERSISTS. THE EXHAUST BRAKES HAVE BEEN SHUTTING OFF AT THE WRONG TIME. THE BRAKES ARE SUPPOSED TO SHUT OFF WHEN COMING TO A STOP OR TRAVELING 15 MPH; HOWEVER, THEY HAVE BEEN SHUTTING OFF WHILE TRAVELING 30-45 MPH. AS A RESULT, THE VEHICLE HAS NO BRAKING SYSTEM. THE VEHICLE HAS BEEN TAKEN TO THE DEALER AND REPAIR SHOPS APPROXIMATELY FOUR TIMES. DURING EACH VISIT, THE MECHANIC REPLACES DIFFERENT PARTS WITHIN THE EXHAUST BRAKING SYSTEM, BUT THEY HAVE BEEN UNABLE TO REPAIR THE FAILURE. SINCE THE VEHICLE IS CURRENTLY NOT UNDER WARRANTY, THE DEALER REFUSES TO REMEDY THE FAILURE. THE FAILURE MILEAGE WAS 3,000 AND CURRENT MILEAGE WAS 14,000. THE FUEL GAUGE WAS INOPERATIVE. THE CONSUMER STATED THE FULE GAUGE PEGS OUT AND IS NOT ACCURATE. THE CRUISE CONTROL WAS INOPERATIVE. UPDATED 02/04/09. *JB

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2005-11-07

VEHICLE SPEED CONTROL PROBLEM

Date Of Incident: 2005-10-31
VIN: 1GBE5U1E15F
Components: VEHICLE SPEED CONTROL
Summary: DT: THE CONTACT STATED WHILE CHANGING LANES, WITH THE CRUISE CONTROL ON , THE VEHICLE STALLED. THE VEHICLE HAS NOT BEEN INSPECTED YET. *AK

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2005 Chevrolet Kodiak recalls

The National Highway Traffic Safety Administration (NHTSA) has issued 3 recalls for different components of the 2005 Chevrolet Kodiak.

2007-10-04

Manufacturer: GENERAL MOTORS CORP.
Components: STEERING
Summary: ON CERTAIN MEDIUM DUTY TRUCKS EQUIPPED WITH ZF MODEL 8018 STEERING GEARS, THE STEERING GEAR MAY HAVE BEEN PRODUCED INCORRECTLY. A STEERING GEAR WITH THIS CONDITION MAY PRODUCE THE FEELING OF HITTING A CURB AND A CRACKING OR PINGING SOUND WHEN THE STEERING WHEEL IS TURNED.
Consequence: THE STEERING WHEEL POSITION MAY BE OFF-CENTER AND INCREASED EFFORT MAY BE REQUIRED WHEN TURNING, INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL INSPECT FOR CERTAIN DATE CODES AND VERIFY THE MILEAGE ON STEERING GEARS AND REPLACE GEARS AS NECESSARY. THE RECALL BEGAN ON OCTOBER 25, 2007. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438; GMC AT 1-866-996-9463; OR ISUZU AT 1-800-255-6727.

2005-06-16

Manufacturer: GENERAL MOTORS CORP.
Components: SERVICE BRAKES, HYDRAULIC:FLUID
Summary: CERTAIN 2003-2005 MODEL YEAR 4500/5500 SERIES CHEVROLET KODIAK, SCHOOL BUS CHASSIS, AND GMC TOPKICK VEHICLES; AND 2003-2004 MODEL YEAR GMC SCHOOL BUS CHASSIS VEHICLES EQUIPPED WITH AN 8.1L ENGINE AND HYDROMAX BRAKE SYSTEM. THE POWER STEERING HOSE MAY COME INTO CONTACT WITH A PORTION OF THE INTERMEDIATE STEERING SHAFT. A HOLE COULD BE WORN IN THE HOSE AND A LOSS OF HYDRAULIC FLUID WOULD OCCUR.
Consequence: IF THERE IS SUFFICIENT AMOUNT OF FLUID LOSS, THE DRIVER WILL HEAR A NOISE FROM THE POWER STEERING PUMP, THE BRAKE WARNING LIGHT AND WARNING TONE WILL ACTIVATE. INCREASED EFFORT MAY BE REQUIRED FOR STEERING AND BRAKING, INCREASING THE RISK OF A CRASH.
Remedy: GM WILL NOTIFY ITS CUSTOMERS AND DEALERS WILL REROUTE THE POWER STEERING HOSE. IF THE STEEL BRAIDING OF THE HOSE IS EXPOSED, DEALERS ARE TO REPLACE THE HOSE FREE OF CHARGE. THE RECALL BEGAN ON JULY 12, 2005. OWNERS MAY CONTACT CHEVROLET AT 800-630-2438 OR GMC AT 866-996-9463.

2005-02-08

Manufacturer: GENERAL MOTORS CORP.
Components: SERVICE BRAKES, HYDRAULIC
Summary: CERTAIN TRUCKS, SPORT UTILITY VEHICLES, AND VANS EQUIPPED WITH BOSCH HYDRO-BOOST BRAKE ASSEMBLIES, THE HYDRAULIC BRAKE BOOSTER PRESSURE ACCUMULATOR MAY CRACK AND SEPARATE FROM THE HYDRO-BOOST ASSEMBLY DURING NORMAL OPERATING CONDITIONS.
Consequence: IF A SEPARATION OCCURRED AND THE HOOD OF THE VEHICLE WERE OPEN, FRAGMENTS FROM THE ACCUMULATOR COULD CAUSE INJURY TO PEOPLE IN THE IMMEDIATE AREA. THE PRESENCE OF THIS CRACK OR FRACTURED SURFACE COULD ALLOW THE HYDRAULIC FLUID TO LEAK FROM THE ACCUMULATOR CIRCUIT OF THE BOOSTER ASSEMBLY. THE LOSS OF FLUID WOULD CAUSE INCREASED STEERING AND BRAKING EFFORT AND A CRASH MAY OCCUR WITHOUT PRIOR WARNING.
Remedy: DEALERS WILL TEST THE HYDRO-BOOST ASSEMBLY FOR FUNCTIONAL OPERATION OF THE TWO-FUNCTION VALVE. IF THE HYDRO-BOOST ASSEMBLY FAILS THE TEST, DEALERS WILL REPLACE THE ASSEMBLY FREE OF CHARGE. THE RECALL BEGAN ON MARCH 23, 2005. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438, GMC TRUCKS AT 1-866-996-9463 AND HUMMER AT 1-800-732-5493.

Additional sources

More sources of information about 2005 Chevrolet Kodiak problems:

Common Problems/Issues with c4500/c5500 | Diesel Place

https://www.dieselplace.com/threads/common-problems-issues-with-c4500-c5500.444384/

Jan 15, 2012 ... ok maybe a Freightliner Sportchassis LOL . 2007 Chevy Kodiak 4500 with 22.5s :D DECEMBER 2012 DIESEL PLACE TRUCK ...

Glow plug issues. Relay? | Chevy and GMC Duramax Diesel Forum

https://www.duramaxforum.com/threads/glow-plug-issues-relay.337586/

Jan 21, 2014 ... But will start even without it each time. Pete. 2005 Chevy Kodiak c5500 with a 350HP 5.9 cummins and 6 speed Allison trans. DRW Club # 212.

Common Problems/Issues with c4500/c5500 | Page 2 | Diesel Place

https://www.dieselplace.com/threads/common-problems-issues-with-c4500-c5500.444384/page-2

kodiak. · Registered. Joined Jun 15, 2005. ·. 1,475 Posts.

Help please 2005 C5500 RV | Chevy and GMC Duramax Diesel ...

https://www.duramaxforum.com/threads/help-please-2005-c5500-rv.467434/

Jul 29, 2014 ... Kodiak & Topkick Forum. JavaScript is ... I just purchased a used 2005 Chevy C 5500 Gulfsteam RV. ... There are two common problems with the LLY ...