2005 GMC Sierra 3500 Service and Repair Manual

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Factory-Grade Data

2005 GMC Sierra 3500 service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • WT Crew Cab Pickup 4-Door
  • Base Standard Cab Pickup 2-Door
  • SLT Crew Cab Pickup 4-Door
  • Base Extended Cab Pickup 4-Door
  • WT Extended Cab Pickup 4-Door
  • Base Crew Cab Pickup 4-Door
  • Base Cab & Chassis 4-Door
  • Base Cab & Chassis 2-Door
  • SLE Extended Cab Pickup 4-Door
  • WT Cab & Chassis 4-Door
  • SLE Cab & Chassis 4-Door
  • WT Cab & Chassis 2-Door
  • SLE Cab & Chassis 2-Door
  • SLE Crew Cab Pickup 4-Door
  • SLT Extended Cab Pickup 4-Door
  • WT Standard Cab Pickup 2-Door
  • SLE Standard Cab Pickup 2-Door

Engines covered

  • 6.6L 6599CC 403Cu. In. V8 DIESEL OHV Turbocharged
  • 6.0L 5967CC 364Cu. In. V8 GAS OHV Naturally Aspirated
  • 8.1L 496Cu. In. V8 GAS OHV Naturally Aspirated
  • 6.0L 5967CC 364Cu. In. V8 CNG OHV Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2005 GMC Sierra 3500 Recalls & Complaints

NHTSA #06E04300019/05/2006Component: FUEL SYSTEM, GASOLINE

CERTAIN REPLACEMENT FUEL FILTERS, FRAM BRAND NAME P/N G3727, WITH DATE CODES X52911 THROUGH X60801 SEQUENTIALLY OR X600141 AND A MEXICO COUNTRY OR ORIGIN MARKING ON THE FUEL FILTER HOUSING MANUFACTURE

Consequence

THIS CONDITION MAY CAUSE AN INADEQUATE SEAL AT THE CONNECTION, POTENTIALLY LEADING TO A FUEL LEAK. I

Remedy

HONEYWELL WILL NOTIFY OWNERS AND REPLACE THE FUEL FILTERS FREE OF CHARGE. THE RECALL BEGAN ON OCTOB

TSB #11020816

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

TSB #11019074

This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.

TSB #11019073

This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.

TSB #11019072

This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.

TSB #11017252

This service bulletin provides information for dealers/technicians on OnStar Module 2G Sunset Information.

TSB #11012907

This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.

TSB #11010544

This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.

TSB #11008956

This service bulletin provides information for dealers/technicians on When and How to Submit a Field Product Report (FPR) (U.S. and Canada Dealers Only).

Showing the 8 most recent of 144 technical service bulletins on file with NHTSA.

20100317Component: STEERING:HYDRAULIC POWER ASSIST SYSTEMFire reported

TL* THE CONTACT OWNED A 2005 GMC 3500 TRUCK. THE CONTACT STATED THAT THE VEHICLE WAS PARKED OUTSIDE HIS HOME WITH THE ENGINE SHUT OFF. WHILE INSIDE THE HOME, HE HEARD AN UNUSUALLY LOUD EXPLOSION. UPON

20100317Component: STEERING:HYDRAULIC POWER ASSIST:HOSE, PIPING, AND CONNECTIONSFire reported

TL* THE CONTACT OWNED A 2005 GMC 3500 TRUCK. THE CONTACT STATED THAT THE VEHICLE WAS PARKED OUTSIDE HIS HOME WITH THE ENGINE SHUT OFF. WHILE INSIDE THE HOME, HE HEARD AN UNUSUALLY LOUD EXPLOSION. UPON

20240916Component: SERVICE BRAKES, HYDRAULIC

The contact owns a 2005 GMC Sierra 3500. The contact stated that while driving at an undisclosed speed, the vehicle failed to come to a stop while the brake pedal was depressed. The contact stated tha

20170805Component: STEERING

I HAVE HAD THE LOWER STEERING ARM REPLACED THREE TIMES DUE TO A BAD BUSHING. ONCE UNDER WARRANTY & TWICE I HAD TO PAY FOR IT WHICH IS OVER $300.00 EACH TIME. THIS IS NOT AN UNCOMMON PROBLEM WITH THE C

20160909Component: SERVICE BRAKES

TL* THE CONTACT OWNS A 2005 GMC SIERRA 3500. WHEN THE BRAKE PEDAL WAS DEPRESSED AT 20 MPH, THE VEHICLE HESITATED TO RESPOND WITHOUT WARNING. AFTER INSPECTING THE VEHICLE, IT WAS DISCOVERED THAT THE BR

Showing the 5 most serious of 29 complaints filed with NHTSA.

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