2002 GMC W5500 Forward

The 2002 GMC W5500 Forward is a medium-duty cab-over truck often used for delivery services, construction, and other commercial applications. It was commonly equipped with an Isuzu 4HE1-TC 4.8L turbocharged diesel engine producing approximately 175 horsepower and 347 lb-ft of torque. Other engine options included the Isuzu 4BD2T 3.9L turbo diesel, the Isuzu 6BG1 6.5L diesel, and the GM 5.7L Vortec gas. Transmission options varied, typically including Isuzu manual transmissions such as the MSG 5-speed and the Aisin A465 4-speed automatic transmission. Owners appreciate the truck’s maneuverability and relatively compact size for navigating city streets, while common dislikes revolve around its ride quality and the cost of maintaining a commercial vehicle.

Engine

Isuzu 4HE1-TC 4.8L Turbo Diesel

• Injector Failure
  • Description/Symptoms: Rough running engine, white smoke from exhaust, poor fuel economy, engine misfire.
  • Solution: Replace faulty injectors.
  • Estimated Cost to Fix: $500 - $1500+
  • Recalls: None Found
• Turbocharger Failure
  • Description/Symptoms: Loss of power, excessive black smoke, whistling noise from turbo, engine warning light.
  • Solution: Replace or rebuild the turbocharger.
  • Estimated Cost to Fix: $800 - $2500+
  • Recalls: None Found
• Fuel Injection Pump Failure
  • Description/Symptoms: Hard starting, no start, poor performance, stalling.
  • Solution: Replace or rebuild the fuel injection pump.
  • Estimated Cost to Fix: $1000 - $3000+
  • Recalls: None Found

Isuzu 4BD2T 3.9L Turbo Diesel

• Cracked Cylinder Head
  • Description/Symptoms: Overheating, coolant loss, white smoke from exhaust, bubbling in the coolant reservoir.
  • Solution: Replace the cylinder head.
  • Estimated Cost to Fix: $2000 - $4000+
  • Recalls: None Found

Isuzu 6BG1 6.5L Diesel

• Overheating
  • Description/Symptoms: Engine overheating, loss of power, coolant leaks.
  • Solution: Inspect and repair cooling system including radiator, water pump, and thermostat.
  • Estimated Cost to Fix: $300 - $1500+
  • Recalls: None Found

GM 5.7L Vortec Gas

• Intake Manifold Gasket Leak
  • Description/Symptoms: Coolant leak, rough idle, misfires, loss of coolant, overheating.
  • Solution: Replace the intake manifold gasket.
  • Estimated Cost to Fix: $300 - $800+
  • Recalls: None Found

Transmission

Isuzu MSG 5-Speed Manual

• Synchro Wear/Failure
  • Description/Symptoms: Grinding or difficulty shifting into gear, especially 2nd and 3rd gear.
  • Solution: Rebuild or replace the transmission, including replacing worn synchros.
  • Estimated Cost to Fix: $1500 - $4000+
  • Recalls: None Found

Aisin A465 4-Speed Automatic

• Slipping/Harsh Shifting
  • Description/Symptoms: Transmission slipping between gears, harsh or delayed shifts, failure to shift.
  • Solution: Rebuild or replace the transmission. Could also be caused by low fluid or bad fluid, so start by checking that.
  • Estimated Cost to Fix: $200 - $4000+
  • Recalls: None Found

Suspension

• Leaf Spring Sagging/Breakage
  • Description/Symptoms: Vehicle leaning to one side, reduced load capacity, rough ride.
  • Solution: Replace the leaf springs.
  • Estimated Cost to Fix: $500 - $1500+ per spring
  • Recalls: None Found
• Worn Shocks
  • Description/Symptoms: Bouncy ride, poor handling, excessive body roll.
  • Solution: Replace the shocks.
  • Estimated Cost to Fix: $200 - $800+ for all shocks
  • Recalls: None Found

Electrical

• Wiring Harness Issues
  • Description/Symptoms: Intermittent electrical problems, lights flickering, starting issues, sensor malfunctions. Often caused by corrosion or damaged wiring due to truck’s age and environment.
  • Solution: Repair or replace the affected wiring harness.
  • Estimated Cost to Fix: $100 - $1000+ depending on the severity
  • Recalls: None Found
• Alternator Failure
  • Description/Symptoms: Battery not charging, dimming lights, vehicle stalling.
  • Solution: Replace the alternator.
  • Estimated Cost to Fix: $200 - $600+
  • Recalls: None Found

Exterior

• Rust
  • Description/Symptoms: Rust on the frame, body panels, and undercarriage. Common in areas with harsh winters or coastal environments.
  • Solution: Repair or replace rusted panels, treat and protect the frame.
  • Estimated Cost to Fix: $100 - $Varies greatly depending on severity
  • Recalls: None Found

Interior

• HVAC Blower Motor Failure
  • Description/Symptoms: Blower motor not working, no airflow from vents.
  • Solution: Replace the blower motor.
  • Estimated Cost to Fix: $100 - $400+
  • Recalls: None Found

Summary

The 2002 GMC W5500 Forward, being a medium-duty commercial vehicle, faces typical issues associated with its usage and age. Engine and transmission problems are common, especially concerning fuel system components, turbochargers, and synchro wear. Suspension issues, particularly leaf spring fatigue, can affect ride quality and load capacity. Electrical problems stemming from wiring harness degradation are also frequently reported. The severity and cost of these issues can vary widely, with some repairs being relatively inexpensive while others, such as engine or transmission rebuilds, can be quite costly. Preventative maintenance, especially concerning the cooling system, and addressing rust promptly are crucial for long-term reliability.