2002 Chevrolet W5500 Tiltmaster

Introduction to the 2002 Chevrolet W5500 Tiltmaster

The 2002 Chevrolet W5500 Tiltmaster is a heavy-duty truck known for its durability and towing capabilities. It is available with a range of engine and transmission options. The 6.6L Duramax turbodiesel V8 engine produces 300 horsepower and 620 lb-ft of torque, while the 8.1L Vortec gasoline V8 engine generates 340 horsepower and 455 lb-ft of torque. Transmission options include a 6-speed manual transmission and an Allison 5-speed automatic transmission. Drivers appreciate its spacious cabin and comfortable ride, but some owners have reported issues with various components.

Engine

6.6L Duramax Turbodiesel V8

• Fuel Injector Failure:

  • Description/Symptoms: Difficulty starting, black smoke from exhaust, rough idling.
  • Solution: Replace failed fuel injectors.
  • Estimated Cost to Fix: $1,000 - $2,000+

• Turbocharger Wastegate Sticking:

  • Description/Symptoms: Reduced power, increased exhaust temperature.
  • Solution: Clean or replace turbocharger wastegate.
  • Estimated Cost to Fix: $500 - $1,000

• Exhaust Gas Recirculation (EGR) Valve Failure:

  • Description/Symptoms: Engine stalling, poor performance, increased emissions.
  • Solution: Replace EGR valve.
  • Estimated Cost to Fix: $500 - $1,000

• Head Gasket Failure:

  • Description/Symptoms: Engine overheating, white smoke from exhaust, coolant loss.
  • Solution: Replace head gasket.
  • Estimated Cost to Fix: $2,000 - $3,000+

8.1L Vortec Gasoline V8

• Ignition Coil Failure:

  • Description/Symptoms: Engine misfires, rough idling, poor performance.
  • Solution: Replace ignition coils.
  • Estimated Cost to Fix: $100 - $200 per coil

• Fuel Pump Failure:

  • Description/Symptoms: Difficulty starting, engine stalling, loss of power.
  • Solution: Replace fuel pump.
  • Estimated Cost to Fix: $500 - $1,000

• Intake Manifold Gasket Leak:

  • Description/Symptoms: Coolant leak, engine overheating, poor performance.
  • Solution: Replace intake manifold gasket.
  • Estimated Cost to Fix: $300 - $500

Transmission

6-Speed Manual Transmission

• Synchronizer Failure:

  • Description/Symptoms: Difficulty shifting gears, grinding noise when shifting.
  • Solution: Replace synchronizers.
  • Estimated Cost to Fix: $1,000 - $2,000

Allison 5-Speed Automatic Transmission

• Valve Body Failure:

  • Description/Symptoms: Harsh shifting, slipping gears, overheating.
  • Solution: Rebuild or replace valve body.
  • Estimated Cost to Fix: $1,500 - $2,500

• Torque Converter Lockup Failure:

  • Description/Symptoms: Transmission slipping, vibration, engine overheating.
  • Solution: Replace torque converter.
  • Estimated Cost to Fix: $1,000 - $2,000

Suspension

• Front Leaf Spring Failure:

  • Description/Symptoms: Sagging front end, poor handling, uneven tire wear.
  • Solution: Replace leaf springs.
  • Estimated Cost to Fix: $500 - $1,000 per axle

• Rear Axle Bearing Failure:

  • Description/Symptoms: Grinding noise from rear axle, vibration.
  • Solution: Replace rear axle bearings.
  • Estimated Cost to Fix: $500 - $1,000 per axle

Electrical

• Alternator Failure:

  • Description/Symptoms: Dim headlights, difficulty starting, battery discharge.
  • Solution: Replace alternator.
  • Estimated Cost to Fix: $500 - $1,000

• Battery Drain:

  • Description/Symptoms: Battery loses charge quickly, requires frequent charging.
  • Solution: Check battery and electrical system for parasitic draw.
  • Estimated Cost to Fix: $100 - $500+

Exterior

• Rust on Frame:

  • Description/Symptoms: Corrosion on frame, weakened structural integrity.
  • Solution: Rust treatment and undercoating.
  • Estimated Cost to Fix: $500 - $1,500+

• Headlight Switch Failure:

  • Description/Symptoms: Headlights do not turn on or off, intermittent operation.
  • Solution: Replace headlight switch.
  • Estimated Cost to Fix: $100 - $200

Interior

• Seat Heater Failure:

  • Description/Symptoms: Seat heaters do not work.
  • Solution: Replace seat heater elements or control module.
  • Estimated Cost to Fix: $200 - $500 per seat

Recalls:

• NHTSA Recall 02V233000: Fuel tank overfilling
• NHTSA Recall 02E013000: Airbag control module failure
• NHTSA Recall 02E003000: Seatbelt anchor failure

Summary

While the 2002 Chevrolet W5500 Tiltmaster is a capable heavy-duty truck, it has been known to experience some issues. The most common problems include fuel injector failure, turbocharger wastegate sticking, and transmission valve body failure. While the severity of these issues varies, some of them can be costly to repair. However, overall, the W5500 is a reliable truck with a proven track record in towing and hauling applications.