2009 GMC W5500 Forward

The 2009 GMC W5500 Forward is a medium-duty cab-over truck primarily used for commercial applications. It was available with a 5.2L Isuzu 4HK1-TC turbocharged diesel engine, producing around 200 horsepower and 441 lb-ft of torque. Some owners appreciate the truck’s maneuverability in urban environments and its high payload capacity. However, common complaints include parts availability issues and some reliability concerns related to specific components. The truck typically came with an Aisin A465 6-speed automatic transmission.

Engine

5.2L Isuzu 4HK1-TC Diesel

• Turbocharger Failure
  • Description/Symptoms: Loss of power, excessive black smoke from the exhaust, whining noise from the turbocharger, possible engine damage if fragments enter the engine.
  • Solution: Replace the turbocharger. Inspect the oil supply line to the turbocharger for blockages and replace if necessary.
  • Estimated Cost to Fix: $2,000 - $4,000+
  • Recalls: None Found
• Diesel Particulate Filter (DPF) Clogging/Failure
  • Description/Symptoms: Reduced engine power, increased fuel consumption, DPF warning light illuminated, potential for engine shutdown. This can be due to short drive cycles where the DPF is not able to regenerate properly or a faulty sensor in the exhaust system.
  • Solution: Attempt manual DPF regeneration. If regeneration fails, the DPF may need to be cleaned or replaced. Diagnose and repair any underlying issues causing excessive soot production.
  • Estimated Cost to Fix: $800 - $3,000+ depending on the repair.
  • Recalls: None Found
• Injector Failure
  • Description/Symptoms: Rough idle, misfires, poor fuel economy, excessive smoke from the exhaust.
  • Solution: Replace the faulty injector(s). Ensure proper fuel filtration to prevent future injector issues.
  • Estimated Cost to Fix: $500 - $2,000+ depending on the number of injectors replaced and labor costs.
  • Recalls: None Found

Transmission

Aisin A465 6-Speed Automatic

• Shifting Problems/Slipping
  • Description/Symptoms: Delayed shifts, harsh shifts, slipping between gears, transmission warning light illuminated. This can be caused by worn clutch packs, valve body issues, or low transmission fluid.
  • Solution: Perform a transmission fluid flush and filter change. If the problem persists, further diagnostics are required, which may involve valve body repair or replacement, or a complete transmission rebuild or replacement.
  • Estimated Cost to Fix: $300 (fluid/filter) - $5,000+ (rebuild/replace)
  • Recalls: None Found

Suspension

• Leaf Spring Sagging/Breakage
  • Description/Symptoms: Vehicle leaning to one side, reduced ride height, poor handling, noticeable cracks or breaks in the leaf springs.
  • Solution: Replace the worn or broken leaf springs. Consider upgrading to heavier-duty springs if the vehicle is consistently carrying heavy loads.
  • Estimated Cost to Fix: $500 - $1,500+ per axle.
  • Recalls: None Found
• Worn Shocks/Struts
  • Description/Symptoms: Bouncy ride, poor handling, excessive body roll during cornering, premature tire wear.
  • Solution: Replace the worn shocks or struts.
  • Estimated Cost to Fix: $200 - $800+ depending on the brand and labor.
  • Recalls: None Found

Electrical

• Wiring Harness Issues
  • Description/Symptoms: Intermittent electrical problems, such as lights flickering, gauges malfunctioning, or starting problems. Corrosion and damaged wiring are common causes due to exposure to the elements.
  • Solution: Inspect the wiring harness for damage and repair or replace as necessary. Clean corroded connections.
  • Estimated Cost to Fix: $100 - $1,000+ depending on the severity and location of the issue.
  • Recalls: None Found
• Alternator Failure
  • Description/Symptoms: Battery warning light illuminated, dimming headlights, difficulty starting, dead battery.
  • Solution: Replace the alternator. Check the battery and charging system for any other issues.
  • Estimated Cost to Fix: $300 - $700+
  • Recalls: None Found

Exterior

• Rust/Corrosion
  • Description/Symptoms: Rust forming on the frame, cab, and other exterior components. This is more common in areas with high salt exposure.
  • Solution: Treat and repair rust spots. Apply rust preventative coatings to protect against future corrosion.
  • Estimated Cost to Fix: $100 - $2,000+ depending on the severity and extent of the rust.
  • Recalls: None Found

Interior

• HVAC Blower Motor Failure
  • Description/Symptoms: Blower motor not working, weak airflow, unusual noises from the blower motor area.
  • Solution: Replace the blower motor.
  • Estimated Cost to Fix: $150 - $400+
  • Recalls: None Found
• Seat Frame Issues
  • Description/Symptoms: Broken or bent seat frames can cause discomfort or instability while driving
  • Solution: Weld the seat frame back together or completely replace it
  • Estimated Cost to Fix: $100 - $500+ depending on labor to remove/replace and cost of the frame itself
  • Recalls: None Found

Summary

The 2009 GMC W5500 Forward, while valued for its functionality, does exhibit some common issues. Engine problems related to the turbocharger, DPF, and injectors are among the more costly concerns. Transmission issues can also be expensive to address. Suspension and electrical problems can contribute to downtime and maintenance costs. Overall, potential buyers should carefully inspect the vehicle and be prepared for potential repairs, particularly related to the engine and emissions systems. The severity of issues varies, but repairs can range from a few hundred dollars to several thousand, making pre-purchase inspection crucial.