2005 Chevrolet T6500

The 2005 Chevrolet T6500 is a medium-duty truck, typically used for commercial applications. It’s appreciated for its robust build and versatility, though some owners find the ride quality and fuel economy less than ideal. The 2005 Chevrolet T6500 typically features a Duramax 6.6L diesel engine. Horsepower and torque will vary depending on the specific tuning and configuration but can range from 250 - 330 HP and 520 - 650 lb-ft. Other engine options may include the Vortec 8.1L gasoline V8. Transmission options usually consist of Allison automatic transmissions, such as the 1000 or 2000 series.

Engine

Duramax 6.6L Diesel

• Fuel Injector Failure
  • Description/Symptoms: Hard starting, rough idle, white or black smoke from the exhaust, decreased fuel economy, and engine misfires. Can lead to complete engine failure if not addressed.
  • Solution: Replace faulty fuel injectors with updated versions. Thoroughly clean the fuel system to prevent future contamination.
  • Estimated Cost to Fix: $400 - $800 per injector, plus labor.
  • Recalls: None Found
• Turbocharger Failure
  • Description/Symptoms: Whining or screeching noises from the turbocharger, loss of power, black smoke from the exhaust, and potentially engine stalling. Can be caused by oil starvation, foreign object damage, or general wear and tear.
  • Solution: Replace the faulty turbocharger with a new or remanufactured unit. Address any underlying issues causing the failure, such as oil leaks or contamination.
  • Estimated Cost to Fix: $1,500 - $3,000+
  • Recalls: None Found

Vortec 8.1L Gasoline V8

• Exhaust Manifold Leaks
  • Description/Symptoms: Ticking or hissing noise, especially when the engine is cold. Burning smell under the hood. Decreased fuel economy and performance.
  • Solution: Replace the warped or cracked exhaust manifold and gaskets.
  • Estimated Cost to Fix: $500 - $1,200+
  • Recalls: None Found

Transmission

Allison 1000/2000 Series Automatic

• Torque Converter Failure
  • Description/Symptoms: Shuddering or vibrations during acceleration, especially at lower speeds. Slipping between gears. Overheating of the transmission.
  • Solution: Replace the faulty torque converter. Inspect and repair any related transmission damage caused by the failure. Flush cooler lines, and replace filter.
  • Estimated Cost to Fix: $1,800 - $3,500+
  • Recalls: None Found
• Internal Seal Leaks
  • Description/Symptoms: Transmission fluid leaks, slipping between gears, delayed engagement, and rough shifting.
  • Solution: Remove and disassemble transmission. Replace internal seals and gaskets. Reassemble and install, replacing fluid and filter.
  • Estimated Cost to Fix: $1,500 - $4,000+
  • Recalls: None Found

Suspension

• Leaf Spring Sagging/Failure
  • Description/Symptoms: Vehicle sagging to one side or in the rear, reduced ride quality, increased body roll, and potential damage to other suspension components.
  • Solution: Replace the worn or broken leaf springs with new units. Consider upgrading to heavier-duty springs for increased load capacity.
  • Estimated Cost to Fix: $500 - $1,500 per axle
  • Recalls: None Found
• Worn Ball Joints/Tie Rods
  • Description/Symptoms: Loose steering, wandering on the road, clunking noises from the front end, and uneven tire wear.
  • Solution: Replace worn ball joints and tie rod ends. Perform a wheel alignment after the repairs.
  • Estimated Cost to Fix: $300 - $800+ per side.
  • Recalls: None Found

Electrical

• Glow Plug Issues (Diesel)
  • Description/Symptoms: Hard starting, excessive smoke, rough running when cold.
  • Solution: Replace failed glow plugs.
  • Estimated Cost to Fix: $200 - $600+
  • Recalls: None Found
• Wiring Harness Problems
  • Description/Symptoms: Intermittent electrical issues, such as malfunctioning lights, sensors, or accessories. Corrosion, damaged connectors, and chafing can lead to shorts and open circuits.
  • Solution: Inspect and repair damaged wiring harnesses. Replace corroded connectors and apply dielectric grease to prevent future issues.
  • Estimated Cost to Fix: $100 - $1,000+ (depending on the severity and location of the damage).
  • Recalls: None Found

Exterior

• Corrosion
  • Description/Symptoms: Rust formation in wheel wells, undercarriage, and body panels.
  • Solution: Remove rust, treat the affected area, and apply a protective coating. Address any underlying issues causing the corrosion, such as poor drainage or exposure to road salt.
  • Estimated Cost to Fix: $200 - $2,000+ (depending on the severity).
  • Recalls: None Found

Interior

• HVAC Blower Motor Failure
  • Description/Symptoms: Blower motor not working, only working on some speeds, or making excessive noise.
  • Solution: Replace the faulty blower motor. Inspect and clean the blower motor resistor.
  • Estimated Cost to Fix: $150 - $400+
  • Recalls: None Found

Summary

The 2005 Chevrolet T6500, like most medium-duty trucks, can present a range of issues depending on its usage and maintenance history. Engine problems, particularly with the Duramax diesel, can be costly due to fuel injector and turbocharger failures. Transmission issues, especially with the Allison automatic, also require significant expense. Suspension wear and electrical gremlins are also common. Overall, potential buyers should carefully inspect the vehicle’s service records and perform a thorough pre-purchase inspection, paying close attention to these potential problem areas. The cost to repair these issues can range from a few hundred dollars to several thousand, depending on the specific problem and the extent of the damage.