2009 Chevrolet C5500 Kodiak

The 2009 Chevrolet Kodiak C5500 is a medium-duty truck often used for commercial purposes like towing, hauling, and service work. The truck’s popularity stems from its ruggedness, work-ready capabilities, and relatively simple mechanical design for the time. Owners often appreciate its strong towing capacity and comfortable cabin. However, some common complaints revolve around its fuel economy (especially with the Duramax diesel), ride quality (typical of a heavy-duty truck), and potential maintenance costs associated with its heavy-duty components. For the 2009 C5500 Kodiak, engine options included the 6.0L Vortec gasoline engine, and the 6.6L Duramax diesel. Transmission options generally included the Allison 1000 series automatic transmission. The 6.0L gasoline engine produced around 300 horsepower and 360 lb-ft of torque, while the 6.6L Duramax could produce 330+ horsepower and 620+ lb-ft of torque depending on the specific tuning.

Engine

6.6L Duramax Diesel (LMM)

• Fuel Injector Failure
  • Description/Symptoms: Rough running engine, white smoke from exhaust, decreased fuel economy, potential engine misfires. Often caused by poor fuel quality or wear and tear.
  • Solution: Replace faulty fuel injector(s). Diagnosis with a scan tool to identify the specific injector.
  • Estimated Cost to Fix: $500 - $1200+ per injector (depending on labor rates and parts source)
  • Recalls: None Found
• EGR Cooler Failure
  • Description/Symptoms: Coolant loss, white smoke from exhaust, potential for overheating, reduced engine performance.
  • Solution: Replace the EGR cooler. It’s often recommended to clean or replace the EGR valve simultaneously.
  • Estimated Cost to Fix: $800 - $1500+
  • Recalls: None Found
• Turbocharger Failure
  • Description/Symptoms: Loss of power, excessive black smoke, unusual noises from the turbo, potential check engine light.
  • Solution: Diagnose the turbocharger for leaks, damage, or bearing failure. Replacement or rebuild may be necessary.
  • Estimated Cost to Fix: $1500 - $3000+ (depending on whether it’s a rebuild or replacement)
  • Recalls: None Found

6.0L Vortec Gasoline

• Oil Consumption
  • Description/Symptoms: Excessive oil consumption, blue smoke from exhaust, potentially fouled spark plugs. Can be caused by worn valve seals or piston rings.
  • Solution: Diagnose the source of the oil consumption. Potential repairs include valve seal replacement, piston ring replacement, or engine rebuild/replacement.
  • Estimated Cost to Fix: $1000 - $5000+ (depending on the severity and repair needed)
  • Recalls: None Found
• Exhaust Manifold Leaks
  • Description/Symptoms: Ticking noise, especially when cold, decreased fuel economy, potential exhaust smell in the cabin. Cracked exhaust manifolds are common.
  • Solution: Replace the cracked exhaust manifold(s) and gaskets. It is recommended to replace manifold bolts as well because they may be prone to breakage.
  • Estimated Cost to Fix: $500 - $1000+
  • Recalls: None Found

Transmission

Allison 1000 Series Automatic

• Torque Converter Clutch (TCC) Failure
  • Description/Symptoms: Shuddering at highway speeds, poor fuel economy, potential transmission overheating.
  • Solution: Replace the torque converter. Flushing the transmission and replacing the filter are also recommended.
  • Estimated Cost to Fix: $1500 - $3000+
  • Recalls: None Found
• Shift Solenoid Issues
  • Description/Symptoms: Erratic shifting, hard shifts, failure to shift into certain gears, potential transmission limp mode.
  • Solution: Diagnose with a scan tool to identify the faulty solenoid(s). Replace the affected solenoid(s).
  • Estimated Cost to Fix: $300 - $800+
  • Recalls: None Found
• Internal Leakage/Overheating
  • Description/Symptoms: Transmission fluid leaks, overheating transmission, poor shifting performance, potential transmission damage.
  • Solution: Identify and repair the source of the leak. This could involve replacing seals, gaskets, or other internal components. Transmission cooler inspection and repair may be needed.
  • Estimated Cost to Fix: $500 - $2000+ (depending on the severity and repair needed)
  • Recalls: None Found

Suspension

• Worn Ball Joints/Tie Rod Ends
  • Description/Symptoms: Loose steering, clunking noises from the front end, uneven tire wear, poor handling.
  • Solution: Replace worn ball joints and/or tie rod ends. Alignment is necessary after replacement.
  • Estimated Cost to Fix: $300 - $800+ per side (depending on which parts are replaced)
  • Recalls: None Found
• Leaf Spring Sagging/Cracking
  • Description/Symptoms: Reduced ride height, poor ride quality, potential for bottoming out, visible cracking in the leaf springs.
  • Solution: Replace sagging or cracked leaf springs.
  • Estimated Cost to Fix: $500 - $1500+ per spring (depending on the spring type and labor)
  • Recalls: None Found

Electrical

• Glow Plug Issues (Diesel)
  • Description/Symptoms: Hard starting, especially in cold weather, excessive white smoke on startup.
  • Solution: Diagnose and replace faulty glow plug(s). Check the glow plug control module as well.
  • Estimated Cost to Fix: $200 - $600+
  • Recalls: None Found
• Body Control Module (BCM) Problems
  • Description/Symptoms: Intermittent electrical issues, such as malfunctioning power windows, door locks, or lights.
  • Solution: Diagnose the BCM. Programming or replacement may be necessary.
  • Estimated Cost to Fix: $300 - $1000+
  • Recalls: None Found

Exterior

• Rust Issues
  • Description/Symptoms: Rust forming around wheel wells, rocker panels, and other areas prone to corrosion.
  • Solution: Rust repair and prevention. This could involve sanding, patching, and repainting.
  • Estimated Cost to Fix: $200 - $2000+ (depending on the severity and extent of the rust)
  • Recalls: None Found

Interior

• HVAC Blower Motor Failure
  • Description/Symptoms: No air blowing from the vents, weak airflow, or unusual noises from the blower motor.
  • Solution: Replace the blower motor. Replacing the blower motor resistor is also recommended.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found

Summary

The 2009 Chevrolet Kodiak C5500, while a capable and reliable work truck, can experience several common issues. Engine problems with both the Duramax diesel and Vortec gasoline engines, as well as transmission issues with the Allison 1000 series are the most costly and severe to repair. Suspension and electrical problems can also arise. Rust is a common concern with vehicles of this age. Overall, potential buyers should thoroughly inspect the truck and address any existing issues to ensure long-term reliability. The severity of these issues varies, with some being relatively minor and inexpensive to fix, while others can be quite costly.