1991 Chevrolet C35

Introduction:

The 1991 Chevrolet C35 is a heavy-duty pickup truck that was popular with commercial and recreational users. It was available with a variety of engine and transmission options, including a 7.4L gasoline V8, a 6.2L diesel V8, and a 5-speed manual or a 4-speed automatic transmission. The C35 was known for its powerful engines, rugged construction, and spacious interior. However, like any vehicle, it also had its share of issues.

Engine

7.4L Gasoline V8

• Intake Manifold Gasket Failure:
  • Description/Symptoms: Coolant leaks, rough idle, loss of power
  • Solution: Replace intake manifold gaskets
  • Estimated Cost to Fix: $500 - $1,000+
  • Recalls: None Found
• Distributor Cap and Rotor Failure:
  • Description/Symptoms: Hard starting, misfiring, engine stalling
  • Solution: Replace distributor cap and rotor
  • Estimated Cost to Fix: $100 - $200
  • Recalls: None Found
• Fuel Pump Failure:
  • Description/Symptoms: Engine stalling, loss of power, difficulty starting
  • Solution: Replace fuel pump
  • Estimated Cost to Fix: $300 - $500
  • Recalls: None Found
• Water Pump Failure:
  • Description/Symptoms: Coolant leaks, overheating
  • Solution: Replace water pump
  • Estimated Cost to Fix: $200 - $300
  • Recalls: None Found

6.2L Diesel V8

• Injection Pump Failure:
  • Description/Symptoms: Hard starting, black smoke from exhaust, loss of power
  • Solution: Replace injection pump
  • Estimated Cost to Fix: $2,000 - $3,000+
  • Recalls: None Found
• Turbocharger Failure:
  • Description/Symptoms: Loss of power, excessive smoke from exhaust
  • Solution: Replace turbocharger
  • Estimated Cost to Fix: $1,000 - $2,000+
  • Recalls: None Found
• Fuel Injector Failure:
  • Description/Symptoms: Hard starting, rough idle, loss of power
  • Solution: Replace fuel injectors
  • Estimated Cost to Fix: $500 - $700
  • Recalls: None Found

Transmission

5-Speed Manual

• Clutch Failure:
  • Description/Symptoms: Difficulty shifting gears, slipping clutch
  • Solution: Replace clutch assembly
  • Estimated Cost to Fix: $600 - $1,000
  • Recalls: None Found
• Synchronizer Failure:
  • Description/Symptoms: Grinding noises when shifting gears
  • Solution: Replace synchronizer rings
  • Estimated Cost to Fix: $400 - $600
  • Recalls: None Found

4-Speed Automatic

• Transmission Fluid Leaks:
  • Description/Symptoms: Transmission slipping, difficulty shifting gears
  • Solution: Repair or replace transmission
  • Estimated Cost to Fix: $1,000 - $2,000+
  • Recalls: None Found
• Valve Body Failure:
  • Description/Symptoms: Harsh shifting, transmission slipping
  • Solution: Replace valve body
  • Estimated Cost to Fix: $600 - $1,000
  • Recalls: None Found

Suspension

• Leaf Spring Failure:
  • Description/Symptoms: Sagging rear end, harsh ride
  • Solution: Replace leaf springs
  • Estimated Cost to Fix: $500 - $800
  • Recalls: None Found
• Shock Absorber Failure:
  • Description/Symptoms: Poor ride quality, excessive bouncing
  • Solution: Replace shock absorbers
  • Estimated Cost to Fix: $200 - $300
  • Recalls: None Found
• Stabilizer Bar Links Failure:
  • Description/Symptoms: Clunking noises from front end
  • Solution: Replace stabilizer bar links
  • Estimated Cost to Fix: $100 - $200
  • Recalls: None Found

Electrical

• Alternator Failure:
  • Description/Symptoms: Dimming headlights, battery not charging
  • Solution: Replace alternator
  • Estimated Cost to Fix: $300 - $500
  • Recalls: None Found
• Starter Failure:
  • Description/Symptoms: Engine cranks slowly or not at all
  • Solution: Replace starter
  • Estimated Cost to Fix: $200 - $400
  • Recalls: None Found
• Battery Failure:
  • Description/Symptoms: Dead battery, difficulty starting
  • Solution: Replace battery
  • Estimated Cost to Fix: $100 - $200
  • Recalls: None Found

Exterior

• Rust:
  • Description/Symptoms: Rust on body panels, fenders, and frame
  • Solution: Repair or replace rusted parts
  • Estimated Cost to Fix: Varies widely depending on extent of rust
  • Recalls: None Found
• Headlight Failure:
  • Description/Symptoms: Headlights not working or dim
  • Solution: Replace headlights
  • Estimated Cost to Fix: $100 - $200
  • Recalls: None Found

Interior

• Dashboard Cracking:
  • Description/Symptoms: Cracks in the dashboard
  • Solution: Replace dashboard
  • Estimated Cost to Fix: $300 - $500
  • Recalls: None Found
• Seat Upholstery Tearing:
  • Description/Symptoms: Tears in seat upholstery
  • Solution: Repair or replace seat upholstery
  • Estimated Cost to Fix: $200 - $400
  • Recalls: None Found

Summary

The 1991 Chevrolet C35 is a versatile and powerful workhorse. However, like any vehicle, it has its fair share of issues. The most common and severe issues include injection pump failure on the diesel engine, transmission fluid leaks, and rust. Routine maintenance and repairs can help to prevent some of these issues, but some are simply due to the age and design of the vehicle. The cost of repairs can vary widely depending on the severity of the issue and the availability of parts. Overall, the C35 is a reliable and capable pickup truck that is well-suited for a variety of tasks.