2002 Chevrolet W5500 Tiltmaster

The 2002 Chevrolet W5500 Tiltmaster is a medium-duty cab-over truck primarily used for commercial applications. It’s known for its maneuverability in urban environments and ease of maintenance due to the tilting cab design. Available engine options included the 5.7L gasoline V8, and the 7.8L Isuzu 6HK1-TC diesel inline 6 cylinder engine. The 7.8L Isuzu 6HK1-TC produces approximately 200 horsepower and 441 lb-ft of torque. This truck uses the Aisin A465 4-speed automatic transmission. Owners generally appreciate the truck’s durability and functionality, but common complaints include its somewhat spartan interior and potential for rust in certain climates.

Engine

7.8L Isuzu 6HK1-TC Diesel

• Injector Failure
  • Description/Symptoms: Rough idling, excessive black smoke, loss of power, engine misfires. This is often caused by contaminated fuel or worn injectors.
  • Solution: Replacement of faulty injectors. Ensure fuel system is clean and use appropriate fuel filters.
  • Estimated Cost to Fix: $400 - $800+ per injector (parts and labor)
• Turbocharger Issues
  • Description/Symptoms: Whining noise from the turbo, reduced engine power, excessive oil consumption, and black smoke. Can be due to oil starvation, foreign object damage, or bearing wear.
  • Solution: Inspect turbocharger for damage. Replacement of the turbocharger is typically required.
  • Estimated Cost to Fix: $1500 - $3000+ (parts and labor)
• EGR Valve Problems
  • Description/Symptoms: Rough idling, poor fuel economy, check engine light. Carbon buildup restricts the EGR valve’s movement.
  • Solution: Clean or replace the EGR valve.
  • Estimated Cost to Fix: $200 - $500 (parts and labor)
• Fuel Filter Head Leaks
  • Description/Symptoms: Difficulty starting, fuel leaks, poor fuel economy.
  • Solution: Replacement of the fuel filter head assembly.
  • Estimated Cost to Fix: $300 - $600 (parts and labor)
  • Recalls: None Found

5.7L Gasoline V8

• No Issues Found

Transmission

Aisin A465 4-Speed Automatic

• Shifting Problems
  • Description/Symptoms: Slipping between gears, harsh shifts, failure to shift, or delayed engagement. Often caused by worn clutch packs, valve body issues, or low fluid level.
  • Solution: Check and adjust fluid level. If problems persist, a transmission rebuild or replacement may be necessary. Valve body issues can sometimes be addressed with a valve body replacement or repair.
  • Estimated Cost to Fix: $100 (fluid top off) - $3,000+ (rebuild or replacement)
• Torque Converter Failure
  • Description/Symptoms: Shuddering at low speeds, stalling when coming to a stop, and poor acceleration.
  • Solution: Replacement of the torque converter.
  • Estimated Cost to Fix: $800 - $1500+ (parts and labor)
  • Recalls: None Found

Suspension

• Leaf Spring Sagging/Cracking
  • Description/Symptoms: Vehicle leaning to one side, rough ride, reduced load capacity. Due to age and heavy use.
  • Solution: Replacement of the leaf springs.
  • Estimated Cost to Fix: $500 - $1000+ per spring (parts and labor)
• Worn Shocks/Struts
  • Description/Symptoms: Bouncy ride, poor handling, excessive body roll.
  • Solution: Replacement of shocks/struts.
  • Estimated Cost to Fix: $200 - $500+ per axle (parts and labor)
• Loose/Worn Bushings
  • Description/Symptoms: Clunking noises from the suspension, wandering steering, uneven tire wear.
  • Solution: Replacement of worn bushings in control arms, sway bar links, and other suspension components.
  • Estimated Cost to Fix: $100 - $500+ per component (parts and labor)
  • Recalls: None Found

Electrical

• Wiring Harness Issues
  • Description/Symptoms: Intermittent electrical problems, such as lights flickering, gauges malfunctioning, or starting problems.
  • Solution: Inspect and repair damaged wiring. Replacement of sections of the wiring harness may be necessary.
  • Estimated Cost to Fix: $100 - $1000+ (depending on severity and location)
• Alternator Failure
  • Description/Symptoms: Dim headlights, warning lights on the dashboard, battery not charging.
  • Solution: Replacement of the alternator.
  • Estimated Cost to Fix: $300 - $600 (parts and labor)
• Starter Motor Problems
  • Description/Symptoms: Clicking sound when trying to start the engine, engine not cranking.
  • Solution: Replacement of the starter motor.
  • Estimated Cost to Fix: $200 - $400 (parts and labor)
  • Recalls: None Found

Exterior

• Rust on Cab
  • Description/Symptoms: Rust forming on the cab, particularly around the windshield, door seams, and wheel wells. Common in areas with road salt.
  • Solution: Rust repair or replacement of affected panels. Prevention includes regular washing and application of rust inhibitors.
  • Estimated Cost to Fix: $200+ (per area, depending on severity)
• Headlight Hazing/Yellowing
  • Description/Symptoms: Reduced headlight brightness, yellowed or hazy headlight lenses.
  • Solution: Headlight restoration or replacement.
  • Estimated Cost to Fix: $50 - $200+ (per headlight)
  • Recalls: None Found

Interior

• Dashboard Cracking
  • Description/Symptoms: Cracking of the dashboard due to sun exposure and age.
  • Solution: Dashboard replacement or installation of a dashboard cover.
  • Estimated Cost to Fix: $200 - $800+ (depending on the solution)

Summary

The 2002 Chevrolet W5500 Tiltmaster presents a range of potential issues, largely related to its age and commercial usage. Diesel engine issues such as injector failures and turbocharger problems can be costly to address. Transmission problems and suspension wear are also common. Electrical issues can be complex and require careful diagnosis. Rust can be a significant problem in certain climates. Overall, while the truck is generally considered durable, potential buyers should be aware of these issues and factor in the cost of potential repairs. The severity and cost of repairs can range from minor fixes to major overhauls, so a thorough inspection is crucial before purchasing.