Target Audience:
DIY enthusiasts, Independent Repair Shops, Fleet Maintenance Personnel
Advantages Over Print:
Instant access, searchable content, cross-device compatibility, easier updates, often more cost-effective than multiple printed manuals.
Content Source:
Licensed information derived from OE (Original Equipment) materials by RepairSurge.
Usability:
User-friendly interface, push-button access to information, step-by-step procedures.
Primary Coverage:
Service and Repair
Additional Coverage:
Maintenance, Diagnostics, Troubleshooting, Electrical Schematics, Component Replacement, Specifications
Estimated Page Count:
Varies by specific content, typically thousands of pages in OE equivalent
Manual Type:
Software (Online Service and Repair Manual)
Format:
Digital Access (Web-based, PC/Laptop/Smartphone/Tablet compatible)
Engine:
All gasoline and diesel engines (e.g., 6.0L V8 Vortec, 8.1L V8 Vortec, 6.6L Duramax Diesel)
Transmission:
Automatic transmissions (e.g., 4L80-E, Allison 1000), Manual transmissions (if applicable)
Drivetrain:
Front and Rear Axles, Differentials, Driveshafts, Transfer Case (4WD)
Suspension:
Front Independent Suspension (Torsion Bar), Rear Leaf Spring Suspension, Steering Components
Brakes:
Hydraulic Brake System, ABS, Parking Brake
Electrical:
Wiring Diagrams, Lighting, Power Accessories, Starting and Charging System, ECM/PCM
Body And Chassis:
Body Panels, Doors, Seats, Bumpers, Frame, Glass
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) System
Fuel System:
Fuel Pump, Injectors, Lines, Tank
Cooling System:
Radiator, Fan, Water Pump, Hoses, Thermostat
Maintenance Procedures:
Oil and Filter Changes, Fluid Top-offs, Tire Rotations, Spark Plug Replacement, Air Filter Replacement
Diagnostic Procedures:
Troubleshooting Charts, OBD-II Diagnostics, Component Testing
Repair Procedures:
Engine Mechanical Repairs, Transmission Overhauls, Brake Pad/Rotor Replacement, Suspension Component Replacement, Electrical Component Diagnosis and Replacement
Installation Procedures:
Component Installation and Replacement (e.g., alternator, starter, water pump)
Schematics:
Detailed Electrical Wiring Diagrams for all systems
Depth Of Coverage:
Comprehensive, from basic scheduled maintenance to complete engine/transmission rebuilds and complex electrical diagnostics.
Diagnostics Level:
Advanced diagnostics including symptom-based troubleshooting and component testing with specifications.
Rebuild Information:
Detailed instructions for major component rebuilds, including torque specifications and clearances.
Software Platform:
Web Browser Access
Accessibility:
Accessible on any device with an internet connection and web browser.
Print Capability:
Pages can be printed from the web interface, quality depends on user's printer.
Binding:
N/A (Digital Format)
Paper Type:
N/A (Digital Format)
Licensing Status:
Officially Licensed, OE Material Derived
Subscription Period:
1 Year (with options for extension discounts)
Engine Options:
4.8L V8 Vortec, 5.3L V8 Vortec, 6.0L V8 Vortec, 8.1L V8 Vortec, 6.6L Duramax V8 Turbo Diesel (LB7)
Horse Power Range:
Approx. 255-300 hp for gasoline, 300 hp for Duramax
Torque Range:
Approx. 285-330 lb-ft for gasoline, 520 lb-ft for Duramax
Fuel Delivery Gasoline:
Multi-port Fuel Injection (MPFI)
Fuel System Diesel:
High-pressure Common Rail Injection (Duramax LB7)
Ignition Type:
Distributorless Ignition System (DIS) with Coil-on-Plug (COP) for Vortec engines
Standard Transmission:
4-speed automatic (e.g., 4L60E for lighter duty 2500, 4L80E for heavy duty 2500)
Optional Transmission:
5-speed Allison 1000 automatic (primarily with Duramax diesel), 5-speed manual (less common)
Transmission Features:
Electronic controls, Tow/Haul mode (on automatics), Lock-up torque converter
Body Styles:
Regular Cab, Extended Cab, Crew Cab
Bed Lengths:
Short Bed (approx. 6.5 ft), Long Bed (approx. 8 ft)
Curb Weight Range:
Approx. 5,500 - 7,000 lbs (depending on configuration)
Gross Vehicle Weight Rating Gvwr:
Up to 8,600 lbs (2500 series, depending on configuration)
NHTSA Front Impact Rating:
4-Star (Driver), 5-Star (Passenger) - Check specific configurations
IIHS Front Offset Crash Test:
Good (for models tested, typically up to 2003 for this generation, 2004 data may vary)
Active Safety:
Anti-lock Braking System (ABS), Available StabiliTrak (on some models)
Passive Safety:
Driver and Passenger Front Airbags, Available Side Curtain Airbags (on some models)
Infotainment System:
Base AM/FM stereo, Optional CD player, available premium audio systems. Limited integrated technology compared to modern vehicles.
Driver Assistance Features:
Cruise Control, Optional Park Assist (rear ultrasonic sensors).
Connectivity Options:
Not applicable in the modern sense; primarily basic audio system connections.
Oil Change Interval:
Typically 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (refer to manual for exact specs)
Transmission Fluid Change:
Recommended every 30,000-50,000 miles for heavy-duty use (refer to manual for exact specs)
Coolant Flush:
Every 50,000-100,000 miles or 2-5 years, depending on coolant type (refer to manual)
Engine Oil Specification:
SAE 5W-30 or 10W-30 (API Certified) for gasoline engines; SAE 15W-40 (API CJ-4) for Duramax diesel. Consult manual for precise grade.
Transmission Fluid Type:
Dexron III/VI for automatic transmissions; Allison approved fluid for Allison 1000. Consult manual for exact type.
Coolant Type:
GM P/N 12346340 (Orange, silicate-free, long-life) or equivalent. Consult manual for exact specification.
Common Duramax Issues:
Injectors (LB7), Glow Plugs, Fuel Filter Water Separator Issues
Common Gasoline Engine Issues:
Intake manifold gaskets, PCV valve issues, exhaust manifold leaks (4.8L/5.3L)
Common Transmission Issues:
Torque converter shudder (4L80E), transmission fluid leaks
Common Suspension Issues:
Ball joint wear, tie rod end wear, shock absorber/strut wear
Gmc Truck Legacy:
GMC has a long history of producing robust and capable trucks, emphasizing professional-grade performance.
Sierra Lineage:
The Sierra nameplate replaced the C/K series in 1999. The 2004 model year falls within the first generation of the Sierra, known for its significant redesign and introduction of advanced features like the Duramax diesel.
Manufacturing Locations:
Fort Wayne, Indiana; Oshawa, Ontario, Canada
