2004 Chevrolet T6500

Here’s a breakdown of common issues and complaints for the 2004 Chevrolet T6500, categorized by major components and engine/transmission options. This information is based on common reports and should be used as a guide for potential problem areas. Actual repair costs can vary significantly depending on location, shop rates, and the specific nature of the problem.

The 2004 Chevrolet T6500 is a medium-duty truck often used for commercial applications like delivery services, landscaping, or utility work. Engine options for this year often included the GM 6.0L Vortec gasoline V8, the 7.4L gasoline V8, and the Duramax 6.6L Diesel V8. Transmissions typically included the Allison series automatics, known for their robustness, though specific models can vary. Owners often praised the T6500 for its durability and hauling capacity, but common complaints focused on fuel economy, ride quality, and the cost of maintaining a medium-duty truck. The 6.0L Vortec V8 puts out around 300 horsepower and 360 lb-ft of torque.

Engine

6.0L Vortec V8 (Gasoline)

• Excessive Oil Consumption
  • Description/Symptoms: The engine consumes an abnormally high amount of oil between oil changes, often requiring frequent topping off. Blue smoke from the exhaust is a common symptom.
  • Solution: Diagnosis includes checking for leaks, performing a compression test, and inspecting valve seals and piston rings. Repairs may involve replacing valve seals, piston rings, or a complete engine rebuild.
  • Estimated Cost to Fix: $500 - $5000+ (depending on the extent of repairs)
  • Recalls: None Found
• Intake Manifold Gasket Leak
  • Description/Symptoms: Coolant leak near the intake manifold, leading to overheating and potential engine damage. You may smell coolant or see it dripping.
  • Solution: Replacement of the intake manifold gasket.
  • Estimated Cost to Fix: $300 - $600
  • Recalls: None Found

7.4L Vortec V8 (Gasoline)

• Distributor Issues
  • Description/Symptoms: The distributor pickup coil or ignition module can fail, leading to a no-start condition, misfires, or poor engine performance.
  • Solution: Replacing the distributor pickup coil or the entire distributor assembly.
  • Estimated Cost to Fix: $150 - $400
  • Recalls: None Found

6.6L Duramax Diesel V8 (LB7)

• Injector Failure
  • Description/Symptoms: LB7 Duramax engines are known for injector failures. Symptoms include rough idling, white smoke from the exhaust, fuel in the oil, and decreased fuel economy.
  • Solution: Replacement of the faulty injectors. It’s often recommended to replace all eight injectors simultaneously to ensure balanced performance and avoid future issues.
  • Estimated Cost to Fix: $3,000 - $8,000+ (depending on whether you replace all injectors and labor costs)
  • Recalls: Recall #04034A (04034) addresses fuel injector durability. This recall involves replacing the fuel injectors. It is important to verify if this recall has been performed on the specific vehicle.
• Fuel Injection Pump Failure (CP3)
  • Description/Symptoms: The CP3 high-pressure fuel pump can fail, resulting in a no-start condition or severely reduced engine power.
  • Solution: Replacement of the CP3 fuel pump.
  • Estimated Cost to Fix: $1,500 - $3,000
  • Recalls: None Found
• Turbocharger Issues
  • Description/Symptoms: The turbocharger can experience issues like oil leaks, bearing failure, or wastegate malfunctions, leading to reduced power, excessive smoke, or unusual noises.
  • Solution: Repair or replacement of the turbocharger.
  • Estimated Cost to Fix: $1,000 - $3,500+
  • Recalls: None Found

Transmission

Allison Series Automatic Transmissions (Specific Model Varies by Configuration)

• Shift Flare/Slipping
  • Description/Symptoms: Delayed or harsh shifts, the transmission slipping out of gear, or a general lack of responsiveness.
  • Solution: Diagnosis to identify the cause, which could be worn clutch packs, valve body issues, or solenoid failures. Repairs may involve a transmission rebuild or replacement.
  • Estimated Cost to Fix: $1,500 - $6,000+ (depending on the extent of the damage)
  • Recalls: None Found
• Torque Converter Issues
  • Description/Symptoms: Torque converter shudder, stalling, or failure to lock up properly, resulting in poor fuel economy and reduced performance.
  • Solution: Replacement of the torque converter.
  • Estimated Cost to Fix: $800 - $2,000
  • Recalls: None Found

Suspension

• Leaf Spring Sagging/Failure
  • Description/Symptoms: Rear end sagging, especially when loaded, leading to poor ride quality and reduced load-carrying capacity. Cracked or broken leaf springs.
  • Solution: Replacement of the leaf springs.
  • Estimated Cost to Fix: $500 - $1500+
  • Recalls: None Found
• Worn Ball Joints/Tie Rod Ends
  • Description/Symptoms: Loose steering, clunking noises from the front end, and uneven tire wear.
  • Solution: Replacement of the worn ball joints and/or tie rod ends.
  • Estimated Cost to Fix: $200 - $800
  • Recalls: None Found

Electrical

• Wiring Harness Issues
  • Description/Symptoms: Corrosion or damage to wiring harnesses, especially in areas exposed to the elements. This can lead to various electrical problems, including malfunctioning lights, sensors, or other components.
  • Solution: Repair or replacement of the affected wiring harness.
  • Estimated Cost to Fix: $100 - $1000+ (depending on the extent of the damage and location)
  • Recalls: None Found
• Alternator Failure
  • Description/Symptoms: Battery not charging, dimming lights, and eventually, a no-start condition.
  • Solution: Replacement of the alternator.
  • Estimated Cost to Fix: $200 - $600
  • Recalls: None Found

Exterior

• Rust
  • Description/Symptoms: Rust is common on these trucks, especially in areas exposed to road salt or moisture. Typical locations include the frame, cab corners, rocker panels, and wheel wells.
  • Solution: Rust repair, which can range from minor patching to extensive panel replacement.
  • Estimated Cost to Fix: $200 - $5000+ (depending on the severity)
  • Recalls: None Found

Interior

• HVAC Blower Motor Failure
  • Description/Symptoms: The HVAC blower motor stops working, resulting in no airflow from the vents.
  • Solution: Replacement of the blower motor.
  • Estimated Cost to Fix: $150 - $400
  • Recalls: None Found

Summary

The 2004 Chevrolet T6500, while a robust work truck, has several common issues owners should be aware of. The most significant and costly problems revolve around the Duramax diesel engine (specifically injector failure) and potential transmission issues, particularly with the Allison transmissions. Gas engine models can suffer from oil consumption and intake leaks. Rust is a common concern, especially in colder climates. Overall, potential buyers should carefully inspect the vehicle’s maintenance history and be prepared for potential repairs common to medium-duty trucks. The severity of the issues can range from minor inconveniences to major mechanical failures, with repair costs varying widely depending on the problem.