2004 Chevrolet T8500

Introduction

The 2004 Chevrolet T8500 is a heavy-duty commercial truck with a gross vehicle weight rating (GVWR) of up to 85,000 pounds. It is available with a variety of engine and transmission options, including a 7.2-liter diesel V8 with 215 horsepower and 505 lb-ft of torque, a 7.2-liter turbodiesel V8 with 250 horsepower and 620 lb-ft of torque, and a 7.2-liter turbocharged diesel V8 with 300 horsepower and 720 lb-ft of torque. Transmission options include a 5-speed manual, a 6-speed manual, and a 6-speed automatic.

Drivers appreciate the T8500’s powerful engines, robust suspension, and spacious cabin. However, it has also received criticism for its high price tag and poor fuel economy.

Engine

• 7.2-liter Diesel V8
  • Engine Overheating
    • Description/Symptoms: Engine temperature gauge rises above normal operating range, smoke or steam from engine compartment
    • Solution: Replace thermostat or water pump
    • Estimated Cost to Fix: $200 - $500
    • Recalls: None Found
  • Fuel Injector Failure
    • Description/Symptoms: Difficulty starting, rough idling, loss of power
    • Solution: Replace fuel injectors
    • Estimated Cost to Fix: $500 - $1,000
    • Recalls: None Found
• 7.2-liter Turbodiesel V8
  • Turbocharger Failure
    • Description/Symptoms: Reduced power, black smoke from exhaust
    • Solution: Replace turbocharger
    • Estimated Cost to Fix: $1,000 - $2,500
    • Recalls: None Found
  • Head Gasket Failure
    • Description/Symptoms: Engine overheating, white smoke from exhaust, loss of coolant
    • Solution: Replace head gasket
    • Estimated Cost to Fix: $1,500 - $3,000
    • Recalls: None Found
• 7.2-liter Turbocharged Diesel V8
  • No Issues Found

Transmission

• 5-speed Manual
  • Transmission Noise
    • Description/Symptoms: Grinding or whining noises when shifting
    • Solution: Replace transmission bearings
    • Estimated Cost to Fix: $500 - $1,500
    • Recalls: None Found
  • Clutch Failure
    • Description/Symptoms: Difficulty shifting, slipping, or chattering
    • Solution: Replace clutch
    • Estimated Cost to Fix: $500 - $1,000
    • Recalls: None Found
• 6-speed Manual
  • Shift Fork Failure
    • Description/Symptoms: Difficulty shifting into certain gears
    • Solution: Replace shift fork
    • Estimated Cost to Fix: $300 - $800
    • Recalls: None Found
  • Synchronizer Failure
    • Description/Symptoms: Grinding when shifting gears
    • Solution: Replace synchronizers
    • Estimated Cost to Fix: $500 - $1,200
    • Recalls: None Found
• 6-speed Automatic
  • Transmission Slipping
    • Description/Symptoms: Loss of power, delayed shifting
    • Solution: Replace transmission clutches or solenoids
    • Estimated Cost to Fix: $1,000 - $2,000
    • Recalls: None Found
  • Torque Converter Failure
    • Description/Symptoms: Loss of power, shuddering, overheating
    • Solution: Replace torque converter
    • Estimated Cost to Fix: $1,500 - $2,500
    • Recalls: None Found

Suspension

• Front Axle Wear
  • Description/Symptoms: Clunking or grinding noises when turning, premature tire wear
  • Solution: Replace worn axle components
  • Estimated Cost to Fix: $500 - $1,200
  • Recalls: None Found
• Leaf Spring Failure
  • Description/Symptoms: Sagging or broken leaf springs
  • Solution: Replace leaf springs
  • Estimated Cost to Fix: $200 - $600
  • Recalls: None Found

Electrical

• Battery Drain
  • Description/Symptoms: Battery dies prematurely
  • Solution: Test and replace faulty alternator or starter
  • Estimated Cost to Fix: $200 - $500
  • Recalls: None Found
• Wiring Harness Damage
  • Description/Symptoms: Electrical malfunctions, such as flickering lights or inoperative gauges
  • Solution: Repair or replace damaged wiring harness
  • Estimated Cost to Fix: $300 - $800
  • Recalls: None Found

Exterior

• Rust
  • Description/Symptoms: Rust spots on body panels
  • Solution: Remove rust and apply protective coating
  • Estimated Cost to Fix: Varies depending on severity
  • Recalls: None Found

Interior

• Seat Fabric Tearing
  • Description/Symptoms: Rips or tears in seat upholstery
  • Solution: Repair or replace seat fabric
  • Estimated Cost to Fix: $200 - $500
  • Recalls: None Found
• Dashboard Cracks
  • Description/Symptoms: Cracks or splits in dashboard material
  • Solution: Replace dashboard
  • Estimated Cost to Fix: $300 - $700
  • Recalls: None Found

Summary

Overall, the 2004 Chevrolet T8500 is a reliable and capable commercial truck. However, it is not without its issues. The most common problems reported by owners include engine overheating, fuel injector failure, transmission noise, and seat fabric tearing. While the cost of repairs can vary depending on the severity of the issue, it is important to note that major repairs can be expensive. Potential buyers should consider these issues when evaluating this vehicle.