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2004 GMC W3500 Forward

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By Research the Car 2 min read

Introduction

The 2004 GMC W3500 Forward is a heavy-duty pickup truck known for its rugged capabilities and powerful engine options. It offers several engine and transmission choices, catering to diverse work and towing needs. Despite its strengths, the W3500 Forward has encountered some issues that owners have reported.

Engine

6.6L Duramax Diesel

  • Turbocharger Failure: The turbocharger may fail, resulting in reduced engine power and black smoke from the exhaust. The turbocharger needs to be replaced. $2,000 - $3,000+
  • Diesel Particulate Filter (DPF) Clogging: The DPF may become clogged, causing a drop in performance and a possible limp mode. Cleaning or replacing the DPF is necessary. $500 - $1,500+

8.1L Vortec Gas

  • Intake Manifold Gasket Failure: The intake manifold gasket may fail, leading to coolant and oil leaks, loss of power, and rough idling. Replacing the gasket and associated components is required. $600 - $1,200+

Transmission

Alison 2000 5-Speed Automatic

  • Torque Converter Lockup Clutch Failure: The torque converter lockup clutch may fail, causing shuddering or loss of power during gear changes. The torque converter needs to be replaced. $1,500 - $2,500+
  • Transmission Fluid Leak: The transmission may develop a leak, causing a loss of fluid and decreased performance. Replacing the leaking component or seals is necessary. $300 - $1,000+

Suspension

  • Front Coil Spring Failure: The front coil springs may break or sag, resulting in poor handling and uneven tire wear. Replace the coil springs and inspect other suspension components. $500 - $1,000+
  • Rear Leaf Spring Sagging: The rear leaf springs may sag, leading to a lowered rear end and reduced towing capacity. Replacing or adding helper springs is recommended. $400 - $800+

Electrical

  • Alternator Failure: The alternator may fail, leading to charging issues and a discharged battery. The alternator needs to be replaced. $500 - $1,000+
  • Battery Drain: The battery may drain excessively due to faulty wiring, parasitic draw, or an aging battery. Diagnose and correct the underlying cause. $200 - $600+

Exterior

  • Corrosion on Chrome Trim: The chrome trim pieces may corrode or fade. Replacing or refinishing the trim is an option. $300 - $800+

Interior

  • Radio Display Issues: The radio display may become dim or blank. Replacing the display unit or repairing the circuitry is necessary. $200 - $500+
  • Cup Holder Breakage: The cup holders may break or become loose. Replacing or repairing the cup holder assembly is required. $50 - $150+

Summary

The 2004 GMC W3500 Forward is a capable pickup with a strong engine lineup. However, it faces some common issues related to the turbocharger, gaskets, transmission, and electrical system. The severity of these issues varies, and repairs can be costly. Nevertheless, the W3500 Forward remains a dependable workhorse for those who value its power and utility.

GMC, W3500 Forward
GMC W3500 Forward 2004
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