2005 Saturn Relay
Recalls, most-reported problems, crash-test ratings, fuel economy and what a 2005 Saturn Relay is worth — from official NHTSA and EPA data. 39 on record.
2005 Saturn Relay at a glance
Included: that car's specs and build sheet, model-year recall campaigns and a fair price.
2005 Saturn Relay recalls 3
DORMAN IS RECALLING 979 STEERING KNUCKLES, DORMAN P/NOS. 697-902 AND 697-903, SOLD UNDER DORMAN'S "OE SOLUTIONS<SUP>TM</SUP>" BRAND NAME, AND NAPA P/NOS. 7-8502 AND 7-8503 WHICH WERE SOLD FOR REPLACEMENT USE ON THE VARIOUS VEHICLES LISTED ABOVE. A POTENTIAL MATERIAL OR DESIGN DEFECT COULD RESULT IN THE STEERING KNUCKLE BREAKING IN THE HUB AREA.
Fix: DORMAN WILL NOTIFY OWNERS AND REPLACE THE DEFECTIVE STEERING KNUCKLES FREE OF CHARGE AND REIMBURSE THE REPAIR FACILITY OR OWNER FOR LABOR. THE RECALL BEGAN ON FEBRUARY 23, 2009. OWNERS MAY CONTACT DORMAN'S TOLL-FREE HOTLINE AT 1-800-523-2492 AND PRESS 5.
CERTAIN SPORT UTILITY VEHICLES FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 135, 'PASSENGER CAR BRAKE SYSTEMS.' TO MEET THE STANDARD, THE VEHICLE MUST NOT MOVE FOR FIVE MINUTES WHEN STOPPED ON A STEEP HILL WITH THE PARKING BRAKE APPLIED AND THE VEHICLE IN NEUTRAL (N). SOME OF THESE VEHICLES FAILED THIS TEST.
Fix: DEALERS WILL INSPECT FOR PARKING BRAKE LEVER SLIPPAGE AT EACH REAR BRAKE CALIPER AND REPLACE THE CALIPER IF LEVER SLIPPAGE IS IDENTIFIED. THE RECALL BEGAN ON NOVEMBER 14, 2005. OWNERS MAY CONTACT BUICK AT 1-866-608-8080, CHEVROLET AT 1-800-630-2438, PONTIAC AT 1-800-620-7668, OR SATURN AT 1-800-972…
ON CERTAIN MINIVANS, THE OUTBOARD RELEASE HANDLE ON THE IMPACT-SIDE SECOND-ROW BUCKET SEAT MAY BE ACTUATED AND THE REAR LATCHES MAY UNLATCH EARLY IN A SIDE IMPACT CRASH. THIS WAS DISCOVERED IN A SIDE IMPACT TEST RUN BY GM, UNDER CONDITIONS SIMILAR TO NHTSA'S NEW CAR ASSESSMENT PROGRAM (NCAP) SIDE IMPACT TEST.
Fix: DEALERS WILL REMOVE THE SEAT LATCH RELEASE HANDLE AND INSTALL A BLACK PLASTIC CAP OVER THE EXPOSED METAL STUD TO ELIMINATE THE SIDE IMPACT SAFETY CONCERN FREE OF CHARGE. THE RECALL BEGAN ON APRIL 5, 2005. OWNERS MAY CONTACT SATURN AT 1-800-972-8876, CHEVROLET AT 1-800-630-2438, AND PONTIAC AT 1-800…
Source: U.S. NHTSA, checked 4 Nov 2026. A campaign covers the model year; to see whether a particular car still needs the repair, check its VIN on NHTSA.gov or ask a franchised dealer.
2005 Saturn Relay common problems
The most-reported problem areas across all 91 owner complaints filed with NHTSA — and what to check before you buy.
2005 Saturn Relay safety ratings
Source: NHTSA 5-Star Safety Ratings (NCAP), tested as the 2005 Saturn Relay (Later Release). Ratings can differ by body style and drivetrain.
2005 Saturn Relay MPG & running costs
Source: U.S. EPA / DOE fueleconomy.gov. The EPA lists 2 versions of this model year; combined is shown as a range and the other figures are averages.
What's a 2005 Saturn Relay worth?
Estimated 5-year cost to own
A rough guide to what running a 2005 Saturn Relay costs over five years and 75,000 miles.
How this is estimated: fuel is the U.S. EPA annual cost at 15,000 miles a year. There aren't enough comparable listings to estimate depreciation for this model, so it is left out. Not included: insurance, maintenance, repairs, taxes, registration and finance costs. Treat it as a comparison guide, not a quote.
Dimensions & weight
Manufacturer-reported figures for the 2005 Saturn Relay — ranges cover the 3 body / drivetrain versions on record. Source: Transport Canada vehicle specifications via NHTSA.
Investigations & service bulletins
NHTSA defect investigations 3
POWER SLIDING DOOR Closed
ODI EVALUATED GENERAL MOTORS' (GM) DATA, CONDUCTED CONSUMER INTERVIEWS, INSPECTED AND TESTED MY 2005-2007 GM MINIVANS WITH REGARD TO THE ALLEGED DEFECT OF A POWER SLIDING DOOR (PSD) OPENING WHILE THE VEHICLE IS OUT OF PARK. ODI IDENTIFIED A HIGH WARRANTY CLAIM RATE. HOWEVER, THESE CLAIMS ARE RELATED TO VARIOUS PROBLEMS ASSOCIATED WITH DOORS NOT PROPERLY OPENING OR CLOSING AND NOT SPECIFICALLY TO DOORS OPENING WHILE D…
NHTSA #EA07019 · Latches/locks/linkages, Structure · opened Dec 2007 · closed Feb 2009POWER SLIDING DOOR OPENING Closed
ODI HAS RECEIVED REPORTS THAT THE POWER SLIDING DOORS OPENED WITHOUT COMMAND WHILE THE VEHICLE WAS IN MOTION ON MODEL YEAR 2005 AND 2006 GENERAL MOTORS MINIVANS (CHEVROLET UPLANDER/VENTURE, PONTIAC MONTANA SV6/MONTANA, BUICK TERRAZA, AND SATURN RELAY). SOME REPORTS INDICATE THAT THE DOOR MAY NOT HAVE BEEN CLOSED AND LATCHED BEFORE DRIVING AWAY CAUSING THE DOOR TO REVERSE (OPEN) AT LOW VEHICLE SPEEDS. HOWEVER, OTHER R…
NHTSA #PE07044 · Latches/locks/linkages, Structure · opened Aug 2007 · closed Dec 2007ELECTRICAL HARNESS DAMAGE Closed
THE OFFICE OF DEFECTS INVESTIGATION OPENED THIS INVESTIGATION ON NOVEMBER 29, 2005, BASED ON ONE CONSUMER REPORT TO ODI AND A TECHNICAL SERVICE BULLETIN ISSUED BY GENERAL MOTORS. THE BULLETIN, NO. 1613174, ISSUED ON FEBRUARY 21, 2005, STATES IN PART, "SOME CUSTOMERS MAY REPORT A STALL AND/OR NO CRANK, NO START CONDITION AFTER THE WIPERS ARE USED." ANALYSIS OF THE AVAILABLE DATA INDICATES THAT THE PROBLEM EXPERIENCE O…
NHTSA #PE05063 · Electrical System · opened Nov 2005 · closed Mar 2006An investigation means NHTSA is examining a possible defect — it is not a recall, and many close without one.
Manufacturer service bulletins 547
Technical notes the manufacturer sent to dealers about known issues and fixes. Useful to mention to a mechanic — they are not recalls and repairs may not be covered. Showing the 10 most recent of 547.
This PI directs technician to training regarding sliding door operation.
Bulletin PIT3532C · Jan 2026This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.
Bulletin PIP5601C · Jul 2025This 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.
Bulletin PIT5074R · May 2025This 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.
Bulletin PIT5074R · May 2025This 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.
Bulletin PIT5074R · May 2025This service bulletin provides information for dealers/technicians on OnStar Module 2G Sunset Information.
Bulletin 23-NA-001 · Electrical System · Mar 2025This Preliminary Information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get record a sound clip or take a video of the noise for assessment…
Bulletin PIP5358D · Feb 2025This Preliminary Information communication provides information to the technician about the use of J-35616-64B terminal test probe, replacement terminals, and terminated leads. The J-35616-64B is the latest test probe released for checking tension or probing t…
Bulletin PIT5074Q · Dec 2024This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester and Vehicle Data Record…
Bulletin PIP4723J · Electrical System · Oct 2024This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures…
Bulletin PIT5099H · Sep 2024Source: NHTSA Office of Defects Investigation, listed for the RELAY FWD/AWD. Model-year data, not specific to one car.
Canadian recalls 4
Transport Canada recall campaigns for the 2005 Saturn Relay. Relevant if the car was first sold in, or imported from, Canada.
Other
Issue: This recall is for aftermarket replacement rear window glass produced by Vitro Automotriz. Certain rear window glass may not have been properly tempered. If the window breaks, the glass may separate into large pieces instead of very small ones. Note: This is a voluntary recall that is not being conducted under the requirements of the Motor Vehicle Safety Act. Safety Risk…
Transport Canada #2019420 · Aug 2019Suspension
On certain Aztek (AWD), Montana (AWD), Relay (AWD), RendezVous (AWD), RendezVous (FWD), Silhouette (AWD), Terraza (AWD), Terraza (FWD), Uplander (AWD) and Venture (AWD) vehicles equipped with independent rear suspension, when operated in extreme cold temperature and on rough roads, water and salt can intrude past the ball joint seal. The combination of theses conditions may the…
Transport Canada #2006199 · Aug 2006Brakes
Certain vehicles do not comply with the requirements of CMVSS 135. To meet the Standard, the vehicle must not move for five minutes when stopped on a steep hill with the parking brake applied and the vehicle in NEUTRAL (N). A part that was not manufactured to specifications can cause the parking brake to fail this test. A loud popping noise as the parking brake is applied or a…
Transport Canada #2005184 · Jun 2005Structure
On certain vehicles, the outboard release handle on the impact-side second-row bucket seat may be actuated and the rear latches may unlatch early during the crash sequence of a side impact New Car Assessment Program (NCAP) test. If the rear latches of the seat are released early in a severe side impact, the front outboard latch may disengage and increase the potential for injur…
Transport Canada #2005040 · Feb 2005Source: Transport Canada Motor Vehicle Safety Recalls Database.
About the Saturn Relay
The Saturn Relay is a minivan that was manufactured by the Saturn division of General Motors from 2005-2007 model years. It was a rebadged variant of the Buick Terraza, the Chevrolet Uplander, and the Pontiac Montana SV6, all manufactured in Doraville, Georgia.
From Wikipedia, licensed CC BY-SA 4.0. Describes the model line in general, not this model year specifically.
2005 Saturn Relay trims & engines on record
2005 Saturn Relay vehicles on record
2005 Saturn Relay 25GZDV03L45D164178
2005 Saturn Relay 25GZDV03L95D199380
2005 Saturn Relay 35GZDV23L25D199085
2005 Saturn Relay 25GZDV03L35D225052
2005 Saturn Relay 25GZDV03L05D176151
2005 Saturn Relay 35GZDV23L15D216958
2005 Saturn Relay 25GZDV03L95D243801
2005 Saturn Relay 25GZDV03L85D284548
2005 Saturn Relay 25GZDV03L95D186824
2005 Saturn Relay 35GZDV23LX5D266631
2005 Saturn Relay 35GZDV23L65D183164
2005 Saturn Relay 35GZDV23L25D173943
2005 Saturn Relay 25GZDV03L35D234902
2005 Saturn Relay 25GZDV03L35D185913
2005 Saturn Relay 35GZDV23L05D160964
2005 Saturn Relay 35GZDV23L85D178435
2005 Saturn Relay 25GZDV03L35D157190
2005 Saturn Relay 35GZDX23L85D242502
2005 Saturn Relay 25GZDV03L55D178607
2005 Saturn Relay 35GZDV23L45D208191
2005 Saturn Relay 25GZDV03L65D228589
2005 Saturn Relay 25GZDV03L75D174686
2005 Saturn Relay 35GZDV23L85D240562
2005 Saturn Relay 25GZDV03LX5D155923