1996 GMC W5500 Forward

Introduction

The 1996 GMC W5500 Forward is a heavy-duty pickup truck with a Gross Vehicle Weight Rating (GVWR) of 26,000 lbs. It’s powered by a powerful 7.4L V8 engine, generating 300 horsepower and 455 lb-ft of torque, paired with a 5-speed manual transmission. The W5500 Forward is popular for its impressive towing and hauling capabilities, but it’s not without its issues.

Engine

• 7.4L V8
  • Intake Manifold Gasket Failure: Symptoms include coolant leaks, overheating, and rough idling. Requires replacement of the intake manifold gasket. Estimated Cost to Fix: $500 - $800+
  • Head Gasket Failure: Symptoms include coolant leaks, overheating, and white smoke from the exhaust. Requires replacement of the head gasket(s). Estimated Cost to Fix: $1,500 - $2,500+
  • Oil Pan Gasket Leak: Symptoms include oil leaks from the oil pan. Requires replacement of the oil pan gasket. Estimated Cost to Fix: $200 - $400+
• Recalls:
  • NHTSA Campaign ID: 97V136000: Fuel tank may leak

Transmission

• 5-Speed Manual
  • Transmission Gear Grinding: Symptoms include difficulty shifting gears and grinding noises. May require replacement of synchronizers or other transmission components. Estimated Cost to Fix: $1,000 - $1,500+

Suspension

• Front Suspension:
  • Ball Joint Failure: Symptoms include clunking noises when turning or braking. Requires replacement of the ball joints. Estimated Cost to Fix: $400 - $600+
  • Tie Rod End Failure: Symptoms include loose steering and wobbling. Requires replacement of the tie rod ends. Estimated Cost to Fix: $200 - $400+
• Rear Suspension:
  • Leaf Spring Failure: Symptoms include sagging rear end and poor handling. Requires replacement of the leaf springs. Estimated Cost to Fix: $600 - $800+

Electrical

• Alternator Failure: Symptoms include dimming lights, battery drain, and difficulty starting. Requires replacement of the alternator. Estimated Cost to Fix: $500 - $800+
• Battery Drain: Symptoms include dead battery or difficulty starting. May require replacement of the battery or diagnosis of electrical system components. Estimated Cost to Fix: $100 - $500+
• Recalls:
  • NHTSA Campaign ID: 96V115000: Electrical short may cause fire

Exterior

• Rust on Frame and Undercarriage: Symptoms include rust and corrosion on the frame and undercarriage components. Requires professional rust treatment and repair. Estimated Cost to Fix: Varies widely depending on the extent of damage
• Headlight Bulb Burnout: Symptoms include dim or non-functioning headlights. Requires replacement of the headlight bulbs. Estimated Cost to Fix: $50 - $200+

Interior

• Climate Control Malfunction: Symptoms include malfunctioning heating or air conditioning system. Requires diagnosis and repair of climate control components. Estimated Cost to Fix: $400 - $600+
• Door Panel Switches Failure: Symptoms include non-functioning window switches or door locks. Requires replacement of the door panel switches. Estimated Cost to Fix: $200 - $400+

Summary

The 1996 GMC W5500 Forward has several common issues, particularly with the engine, transmission, and suspension components. However, these issues vary in severity and cost to repair. Overall, the W5500 Forward remains a capable workhorse, but potential buyers should be aware of potential maintenance needs and repair costs.