1991 GMC G2500

1991 GMC G2500 Common Problems

The 1991 GMC G2500 is a full-size pickup truck that was available with a variety of engine and transmission options. It was a popular choice for both commercial and personal use, and it is still a popular choice today. However, like all vehicles, the G2500 has its share of problems.

Engine

• 5.0L V8
  • Intake manifold gasket failure
    • Description/Symptoms: Coolant leaks, overheating, rough idle
    • Solution: Replace intake manifold gaskets
    • Estimated Cost to Fix: $500 - $1000+
    • Recalls: None Found
• 5.7L V8
  • Valve stem seal failure
    • Description/Symptoms: Blue smoke from exhaust, oil consumption
    • Solution: Replace valve stem seals
    • Estimated Cost to Fix: $500 - $1000+
    • Recalls: None Found
• 6.5L V8 Diesel
  • Injector failure
    • Description/Symptoms: Hard starting, rough idle, loss of power
    • Solution: Replace injectors
    • Estimated Cost to Fix: $500 - $1000+
    • Recalls: None Found

Transmission

• 3-speed automatic (THM350)
  • Torque converter failure
    • Description/Symptoms: Slipping gears, loss of power
    • Solution: Replace torque converter
    • Estimated Cost to Fix: $500 - $1000+
    • Recalls: None Found
• 4-speed automatic (THM400)
  • Overdrive failure
    • Description/Symptoms: Loss of overdrive gear
    • Solution: Replace overdrive unit
    • Estimated Cost to Fix: $500 - $1000+
    • Recalls: None Found
• 5-speed manual
  • Synchronizer failure
    • Description/Symptoms: Grinding gears, difficulty shifting
    • Solution: Replace synchronizers
    • Estimated Cost to Fix: $500 - $1000+
    • Recalls: None Found

Suspension

• Front suspension
  • Ball joint failure
    • Description/Symptoms: Clunking noise, loose steering
    • Solution: Replace ball joints
    • Estimated Cost to Fix: $200 - $500+
    • Recalls: None Found
• Rear suspension
  • Leaf spring failure
    • Description/Symptoms: Sagging rear end, rough ride
    • Solution: Replace leaf springs
    • Estimated Cost to Fix: $500 - $1000+
    • Recalls: None Found

Electrical

• Alternator failure
  • Description/Symptoms: Dim lights, dead battery
  • Solution: Replace alternator
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found
• Starter failure
  • Description/Symptoms: No crank
  • Solution: Replace starter
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found
• Wiring harness failure
  • Description/Symptoms: Electrical malfunctions, intermittent problems
  • Solution: Replace wiring harness
  • Estimated Cost to Fix: $500 - $1000+
  • Recalls: None Found

Exterior

• Rust
  • Description/Symptoms: Rust spots on body panels, frame, and undercarriage
  • Solution: Repair or replace rusted parts
  • Estimated Cost to Fix: Varies depending on severity
  • Recalls: None Found

Interior

• Dashboard cracks
  • Description/Symptoms: Cracks in the dashboard
  • Solution: Replace dashboard
  • Estimated Cost to Fix: $500 - $1000+
  • Recalls: None Found
• Seat upholstery wear
  • Description/Symptoms: Worn or torn seat upholstery
  • Solution: Replace seat upholstery
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found

Summary

The 1991 GMC G2500 is a reliable and capable truck, but it is not without its problems. The most common issues are related to the engine, transmission, and suspension. However, these issues are relatively minor and can be fixed for a reasonable cost. Overall, the G2500 is a good value for the money, and it is a good choice for both commercial and personal use.