2009 Chevrolet W5500 Tiltmaster

Here is a breakdown of common issues and complaints related to the 2009 Chevrolet W5500 Tiltmaster, formatted for your website. The Chevrolet W5500 Tiltmaster is a medium-duty cab-over truck popular for its maneuverability and payload capacity in urban environments. The 2009 model year typically came with an Isuzu 4HK1-TC 5.2L Turbo Diesel engine. This engine produced approximately 190 horsepower and 387 lb-ft of torque. Available transmissions were usually an Aisin A465 6-speed automatic or a 5-speed manual transmission. Owners generally appreciate the truck’s tight turning radius and ease of maintenance, but common complaints often revolve around parts availability and certain engine-related issues.

Engine

Isuzu 4HK1-TC 5.2L Turbo Diesel

• Turbocharger Failure
  • Description/Symptoms: Reduced engine power, excessive black smoke from the exhaust, whistling noise from the turbocharger. May trigger a check engine light.
  • Solution: Replacement of the turbocharger. Inspection of oil lines to the turbocharger to ensure proper lubrication is essential.
  • Estimated Cost to Fix: $1,500 - $3,000+
  • Recalls: None Found
• EGR Valve Issues
  • Description/Symptoms: Rough idling, poor fuel economy, and a check engine light. The EGR valve can become clogged with carbon deposits, especially in stop-and-go driving.
  • Solution: Cleaning or replacement of the EGR valve.
  • Estimated Cost to Fix: $300 - $800
  • Recalls: None Found
• Injector Failure
  • Description/Symptoms: Misfires, rough running engine, poor fuel economy, black smoke, and potential engine damage if left unaddressed.
  • Solution: Diagnostic testing to identify the faulty injector(s). Replacement of the failed injector(s).
  • Estimated Cost to Fix: $500 - $1500+ depending on the number of injectors that need to be replaced.
  • Recalls: None Found

Transmission

Aisin A465 6-Speed Automatic

• Harsh Shifting
  • Description/Symptoms: Abrupt or jerky shifts between gears, especially when cold. May be more pronounced between 1st and 2nd gear.
  • Solution: Fluid change with the correct specification fluid. Inspection of the transmission control module (TCM) and solenoids.
  • Estimated Cost to Fix: $200 - $500 for fluid change, $500 - $1500+ for TCM/solenoid issues.
  • Recalls: None Found
• Transmission Slipping
  • Description/Symptoms: Engine revs higher than normal without corresponding acceleration. Delayed engagement when shifting into drive or reverse.
  • Solution: Could be due to low fluid levels, worn clutch packs, or valve body issues. A complete transmission rebuild or replacement may be necessary.
  • Estimated Cost to Fix: $2,500 - $5,000+
  • Recalls: None Found

5-Speed Manual Transmission

• Difficulty Shifting
  • Description/Symptoms: Hard to engage gears, especially when cold. Grinding noises when shifting.
  • Solution: Check and adjust the clutch linkage. Replace worn synchronizers or the entire transmission if necessary.
  • Estimated Cost to Fix: $100-$300 for linkage adjustment, $1,500-$4,000+ for major repairs.
  • Recalls: None Found

Suspension

• Leaf Spring Sagging/Cracking
  • Description/Symptoms: Vehicle sits lower on one side or both, especially when loaded. Visible cracks or broken leaves in the leaf spring packs. Affects ride quality and load capacity.
  • Solution: Replacement of the affected leaf spring pack(s).
  • Estimated Cost to Fix: $500 - $1,500+ per side, depending on the shop and brand of springs.
  • Recalls: None Found
• Worn Shocks/Struts
  • Description/Symptoms: Excessive bouncing after bumps, poor handling, and increased brake distances.
  • Solution: Replacement of the worn shocks or struts.
  • Estimated Cost to Fix: $300 - $800+ per axle, depending on the brand and labor.
  • Recalls: None Found

Electrical

• Wiring Harness Issues
  • Description/Symptoms: Intermittent electrical problems, such as lights flickering, gauges not working correctly, or starting problems. Often caused by corrosion or damaged wiring.
  • Solution: Inspection and repair of the wiring harness, replacing damaged sections or connectors.
  • Estimated Cost to Fix: $200 - $1,000+ depending on the extent of the damage and time required for diagnosis.
  • Recalls: None Found
• Battery Drain
  • Description/Symptoms: Battery dies overnight or after short periods of inactivity.
  • Solution: Diagnosis to identify the parasitic drain (often a faulty relay, aftermarket accessory, or failing component). Repair or replace the faulty component.
  • Estimated Cost to Fix: $100 - $500+ depending on the source of the drain and complexity of the repair.
  • Recalls: None Found

Exterior

• Corrosion
  • Description/Symptoms: Rust forming on the frame, cab, and other metal components.
  • Solution: Removal of the corrosion and application of rust inhibitor and/or painting. Frame repairs or replacement may be necessary in severe cases.
  • Estimated Cost to Fix: $200 - $5,000+ depending on the severity and extent of the corrosion.
  • Recalls: None Found
• Headlight Lens Clouding
  • Description/Symptoms: Headlight lenses become yellowed or cloudy, reducing visibility at night.
  • Solution: Polishing the headlight lenses or replacing the headlight assemblies.
  • Estimated Cost to Fix: $50 - $150 for polishing, $200 - $500+ for replacement.
  • Recalls: None Found

Interior

• HVAC Blower Motor Failure
  • Description/Symptoms: Blower motor stops working or only works on certain settings.
  • Solution: Replacement of the blower motor or the blower motor resistor.
  • Estimated Cost to Fix: $150 - $400+
  • Recalls: None Found

Summary

The 2009 Chevrolet W5500 Tiltmaster is a reliable workhorse, but as with any vehicle of its age, certain issues are more common. Engine-related problems, particularly with the turbocharger and EGR valve, are frequent concerns and can be relatively expensive to repair. Transmission issues can range from minor inconveniences like harsh shifting to more serious problems requiring a rebuild or replacement. Suspension components are also prone to wear and tear, especially under heavy loads. Addressing these issues promptly can help maintain the truck’s reliability and longevity. The severity of the issues ranges from minor inconveniences to potentially disabling problems. The estimated costs vary widely depending on the specific issue, but some repairs can be significant, potentially costing several thousand dollars.