2009 Chevrolet T6500

The 2009 Chevrolet T6500 is a medium-duty commercial truck often used for vocational applications like dump trucks, box trucks, and utility vehicles. Engine options for this model year include the Duramax 6.6L diesel V8, which produces around 330 horsepower and 620 lb-ft of torque, and various gasoline V8 engines. Transmission options include Allison automatic transmissions. Owners generally appreciate the T6500 for its robust build and suitability for demanding work, but common complaints often revolve around maintenance costs associated with commercial vehicles and the reliability of certain components.

Engine

Duramax 6.6L Diesel V8 (LMM)

• Fuel Injector Failure
  • Description/Symptoms: Rough running, hard starting, excessive smoke, decreased fuel economy. Often caused by injector nozzle wear or internal damage.
  • Solution: Replace faulty fuel injector(s). Recalibrate fuel injection control module (FICM).
  • Estimated Cost to Fix: $500-$1000+ per injector replaced (labor and parts).
  • Recalls: None Found
• EGR Cooler Failure
  • Description/Symptoms: Coolant loss, white smoke from exhaust, engine overheating. Corrosion and cracking of the EGR cooler are common.
  • Solution: Replace EGR cooler. Inspect and clean EGR valve.
  • Estimated Cost to Fix: $800 - $1500+
  • Recalls: None Found

Gasoline V8 (Specific Engine Details and Issues Dependent on Engine Type) No Issues Found. Information on gasoline engines for the 2009 Chevrolet T6500 is limited. Accurate information cannot be provided.

Transmission

Allison Automatic Transmissions (1000 Series/2000 Series)

• Torque Converter Failure
  • Description/Symptoms: Shuddering during gear changes, slipping, inability to shift, or complete loss of drive. Internal damage to the torque converter.
  • Solution: Replace torque converter. Flush transmission cooler lines. Inspect transmission for internal damage.
  • Estimated Cost to Fix: $2000-$4000+
  • Recalls: None Found
• Shift Solenoid Failure
  • Description/Symptoms: Erratic shifting, failure to shift, transmission stuck in gear, harsh shifting. Faulty shift solenoids preventing proper gear engagement.
  • Solution: Replace faulty shift solenoids. Inspect wiring harness and TCM.
  • Estimated Cost to Fix: $500-$1500+
  • Recalls: None Found

Suspension

• Leaf Spring Sag/Breakage
  • Description/Symptoms: Vehicle sagging, uneven ride height, clunking noises, compromised handling. Due to heavy loads and frequent use.
  • Solution: Replace worn or broken leaf springs. Inspect and replace U-bolts and shackles as needed.
  • Estimated Cost to Fix: $500-$2000+ per spring (depending on spring pack and labor)
  • Recalls: None Found

Electrical

• Wiring Harness Issues
  • Description/Symptoms: Intermittent electrical problems, lights flickering, sensor malfunctions, starting issues. Damage to wiring harnesses due to exposure to the elements, chafing, and rodent damage.
  • Solution: Inspect and repair damaged wiring harnesses. Replace corroded connectors.
  • Estimated Cost to Fix: $200-$1000+ (depending on the severity and location of damage)
  • Recalls: None Found
• Alternator Failure
  • Description/Symptoms: Dimming lights, battery not charging, warning lights on the dash, eventual stalling. Due to heavy electrical load of commercial vehicles.
  • Solution: Replace faulty alternator. Check battery condition.
  • Estimated Cost to Fix: $300-$800+
  • Recalls: None Found

Exterior

• Rust/Corrosion
  • Description/Symptoms: Rust formation on frame, body panels, and undercarriage, especially in areas exposed to salt and road debris.
  • Solution: Rust repair, panel replacement, application of rust inhibitors.
  • Estimated Cost to Fix: $500-$5000+ (depending on the extent of the rust)
  • Recalls: None Found

Interior

• HVAC Blower Motor Failure
  • Description/Symptoms: No air blowing from vents, weak airflow, unusual noises from the blower motor area. Often caused by debris accumulation or motor wear.
  • Solution: Replace faulty blower motor. Inspect and clean blower motor housing.
  • Estimated Cost to Fix: $200-$500+
  • Recalls: None Found

Summary

The 2009 Chevrolet T6500, while a capable medium-duty truck, experiences common issues associated with commercial vehicles. Engine issues with the Duramax diesel often involve fuel injectors and the EGR cooler, which can be costly to repair. Transmission problems, primarily related to the Allison automatic, include torque converter and shift solenoid failures, also resulting in significant repair expenses. Suspension and electrical issues, such as leaf spring problems and wiring harness damage, are also common. Overall, prospective buyers should be prepared for potential maintenance costs and thoroughly inspect the vehicle’s condition before purchase.