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2004 GMC W5500HD Forward

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By Research the Car 4 min read

Here is a comprehensive list of common issues and complaints associated with the 2004 GMC W5500HD Forward, categorized by major component and engine/transmission option.

The 2004 GMC W5500HD Forward is a medium-duty cab-over truck commonly used for delivery, utility, and service applications. This model year predominantly features the Isuzu 4HK1-TC 5.2L Turbo Diesel engine, producing approximately 200 horsepower and 441 lb-ft of torque. A key strength of the W5500HD is its maneuverability in urban environments due to its cab-over design. However, owners often cite concerns regarding parts availability and relatively high repair costs. Transmission options were typically limited to Isuzu-sourced manual and automatic transmissions.

Engine

Isuzu 4HK1-TC 5.2L Turbo Diesel

  • Injector Failure
    • Description/Symptoms: Misfires, rough idling, white smoke from the exhaust, reduced power, and difficulty starting. Often related to injector clogging or electrical malfunction.
    • Solution: Replacing the faulty injectors. Testing the wiring harness and replacing if needed.
    • Estimated Cost to Fix: $400 - $800+ per injector, plus labor.
    • Recalls: None Found
  • Turbocharger Failure
    • Description/Symptoms: Loss of power, black smoke from the exhaust, whining noises from the turbocharger, and increased oil consumption.
    • Solution: Replacing the turbocharger, inspecting oil lines for blockage.
    • Estimated Cost to Fix: $1500 - $3000+ depending on the turbocharger type and labor.
    • Recalls: None Found
  • EGR Valve Problems
    • Description/Symptoms: Rough idling, poor fuel economy, stalling, and the engine warning light illuminating.
    • Solution: Cleaning or replacing the EGR valve.
    • Estimated Cost to Fix: $200 - $500+
    • Recalls: None Found
  • Fuel Filter Housing Leak
    • Description/Symptoms: Diesel fuel leak under the vehicle near the fuel filter area. Fuel smell present.
    • Solution: Replacing the fuel filter housing assembly.
    • Estimated Cost to Fix: $300 - $600+
    • Recalls: None Found

Transmission

Aisin A465 6-Speed Automatic

  • Slipping and Erratic Shifting
    • Description/Symptoms: Delayed or harsh shifting, transmission slipping during acceleration, and difficulty engaging gears.
    • Solution: Inspection of the transmission fluid (level and condition), followed by a potential transmission rebuild or replacement. Faulty solenoids and valve body issues are common causes.
    • Estimated Cost to Fix: $2500 - $5000+ for rebuild or replacement.
    • Recalls: None Found
  • Torque Converter Issues
    • Description/Symptoms: Shuddering at low speeds, especially during light acceleration. Potential stalling.
    • Solution: Replacing the torque converter.
    • Estimated Cost to Fix: $800 - $1500+
    • Recalls: None Found

Manual Transmission (Specific Model Unspecified)

  • Clutch Failure
    • Description/Symptoms: Clutch slippage, difficulty shifting gears, and unusual noises when engaging the clutch.
    • Solution: Replacing the clutch disc, pressure plate, and throw-out bearing.
    • Estimated Cost to Fix: $800 - $2000+
    • Recalls: None Found

Suspension

  • Leaf Spring Sagging/Breakage
    • Description/Symptoms: Vehicle sitting lower on one side, poor ride quality, and potential cracking or breaking of leaf springs.
    • Solution: Replacing the leaf springs.
    • Estimated Cost to Fix: $500 - $1500+ per side.
    • Recalls: None Found
  • Worn Shocks/Struts
    • Description/Symptoms: Bouncy ride, poor handling, and excessive body roll.
    • Solution: Replacing the shocks/struts.
    • Estimated Cost to Fix: $200 - $600+ per axle.
    • Recalls: None Found
  • Steering Box Wear/Play
    • Description/Symptoms: Excessive play in the steering wheel, difficulty maintaining a straight line, and wandering.
    • Solution: Replacing or rebuilding the steering box.
    • Estimated Cost to Fix: $500 - $1500+
    • Recalls: None Found

Electrical

  • Wiring Harness Issues
    • Description/Symptoms: Intermittent electrical problems, including malfunctioning lights, sensors, and gauges. Corrosion and chafing are common causes.
    • Solution: Repairing or replacing damaged sections of the wiring harness. Cleaning and protecting connections.
    • Estimated Cost to Fix: $200 - $1000+ depending on the extent of the damage.
    • Recalls: None Found
  • Alternator Failure
    • Description/Symptoms: Dimming headlights, battery not charging, and eventual stalling.
    • Solution: Replacing the alternator.
    • Estimated Cost to Fix: $300 - $800+
    • Recalls: None Found

Exterior

  • Rusting/Corrosion
    • Description/Symptoms: Rust formation on the frame, body panels, and undercarriage, especially in areas exposed to road salt.
    • Solution: Addressing rust with cleaning, treatment, and potentially panel replacement.
    • Estimated Cost to Fix: Highly variable, depending on the severity. $200 - $5000+
    • Recalls: None Found

Interior

  • HVAC Blower Motor Failure
    • Description/Symptoms: No air blowing from the vents, or intermittent airflow.
    • Solution: Replacing the blower motor.
    • Estimated Cost to Fix: $150 - $400+
    • Recalls: None Found

Summary

The 2004 GMC W5500HD Forward presents a range of potential issues, with engine-related problems (particularly injector and turbocharger failures) being a significant concern due to their potential cost. Transmission issues, especially with the Aisin automatic, can also be costly. Suspension wear and electrical problems contribute to the overall maintenance burden. Rust is a common issue, depending on the vehicle’s location and usage. While reliable when properly maintained, the W5500HD requires careful inspection and preventative maintenance to avoid expensive repairs. The severity and cost of repairs generally range from moderate to high.

GMC, W5500HD Forward
GMC W5500HD Forward 2004
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