2009 Chevrolet W5500HD Tiltmaster

The 2009 Chevrolet W5500HD Tiltmaster is a medium-duty cab-over truck designed for commercial applications. It was offered with a 5.2L Isuzu 4HK1-TC diesel engine rated at 200 horsepower and 441 lb-ft of torque, coupled with an Aisin A465 6-speed automatic transmission. Owners generally appreciate the truck’s maneuverability in urban environments and its ease of maintenance due to the tilt cab design. Common complaints often revolve around the relatively low horsepower for heavy loads and some reliability issues with certain components.

Engine

5.2L Isuzu 4HK1-TC Diesel

• Fuel Injector Failure
  • Description/Symptoms: Rough running engine, misfires, black smoke, decreased fuel economy, and potential engine damage.
  • Solution: Replace faulty fuel injectors. Recoding of the new injectors may also be needed.
  • Estimated Cost to Fix: $400 - $800+ per injector
  • Recalls: None Found
• Diesel Particulate Filter (DPF) Clogging
  • Description/Symptoms: Reduced engine power, warning lights illuminated, and potential for engine damage if ignored. Frequent regeneration cycles.
  • Solution: DPF cleaning or replacement. Addressing the underlying cause of excessive soot production (e.g., faulty injectors, EGR valve).
  • Estimated Cost to Fix: $500 - $2000+
  • Recalls: None Found
• Exhaust Gas Recirculation (EGR) Valve Failure
  • Description/Symptoms: Rough idle, poor fuel economy, black smoke, and illuminated check engine light.
  • Solution: EGR valve cleaning or replacement.
  • Estimated Cost to Fix: $300 - $700+
  • Recalls: None Found

Transmission

Aisin A465 6-Speed Automatic

• Harsh Shifting
  • Description/Symptoms: Abrupt or jerky shifts between gears, particularly between 2nd and 3rd gear.
  • Solution: Inspect transmission fluid level and condition, perform a transmission flush. If the issue persists, valve body inspection and repair or replacement may be needed.
  • Estimated Cost to Fix: $100 - $1500+
  • Recalls: None Found
• Transmission Slipping
  • Description/Symptoms: Engine revving high without corresponding acceleration, delayed engagement, and transmission warning lights.
  • Solution: Inspect transmission fluid level and condition. Internal damage is possible. Complete rebuild or replacement.
  • Estimated Cost to Fix: $3000 - $6000+
  • Recalls: None Found

Suspension

• Leaf Spring Sagging/Failure
  • Description/Symptoms: Vehicle leaning to one side, reduced load capacity, and rough ride. Cracking or breaking of leaf springs.
  • Solution: Replace worn or broken leaf springs.
  • Estimated Cost to Fix: $400 - $1000+ per spring
  • Recalls: None Found
• Worn Shocks
  • Description/Symptoms: Excessive bouncing, poor handling, and uneven tire wear.
  • Solution: Replace worn shock absorbers.
  • Estimated Cost to Fix: $100 - $400+ per shock
  • Recalls: None Found

Electrical

• Wiring Harness Issues
  • Description/Symptoms: Intermittent electrical problems, difficulty starting, and malfunctioning lights or accessories. Corrosion of wiring connectors is common.
  • Solution: Inspect and repair or replace damaged wiring harnesses and connectors.
  • Estimated Cost to Fix: $100 - $1000+
  • Recalls: None Found
• Alternator Failure
  • Description/Symptoms: Dimming headlights, battery warning light illuminated, and eventual engine stall.
  • Solution: Replace faulty alternator.
  • Estimated Cost to Fix: $300 - $600+
  • Recalls: None Found

Exterior

• Rust
  • Description/Symptoms: Rust forming, especially in areas prone to salt exposure and moisture, such as the frame, cab corners, and undercarriage.
  • Solution: Rust repair, patching affected panels or full panel replacements.
  • Estimated Cost to Fix: $100 - $2,000+
  • Recalls: None Found

Interior

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

Summary

The 2009 Chevrolet W5500HD Tiltmaster, while appreciated for its maneuverability, is prone to issues common to diesel medium-duty trucks of its age. Engine issues, particularly those related to fuel injectors, the DPF, and EGR valve, can be costly to address. Transmission problems, especially harsh shifting and slippage, can also lead to significant repair expenses. Suspension and electrical issues, while generally less costly, can contribute to overall maintenance expenses. Rust is a potential concern in regions with harsh weather conditions. Potential buyers should carefully inspect these areas and factor in potential repair costs.