🏷️ Basic Information

Make:

Chevrolet

Model:

Suburban 2500

Year:

2004

Generation Designation:

GMT800 (Third Generation)

Chassis Code:

GMT830

👋 Introduction

Segment:

Full-size SUV, positioned as a heavy-duty, versatile vehicle for families and commercial use.

Competitors:

Ford Expedition, Dodge Durango, Toyota Sequoia.

Vehicle Strength:

Robust construction, towing capacity, spacious interior, and proven powertrain options.

Convenience:

Instant online access from any internet-connected device, offering superior convenience over traditional printed manuals.

Cost Effectiveness:

Saves significant costs associated with dealership repairs by empowering DIY maintenance and repairs.

Licensing Status:

Officially licensed, derived from OE (Original Equipment) materials, ensuring accuracy and authenticity.

📋 Manual Details

Coverage Summary:

Comprehensive service and repair for all major vehicle systems.

Estimated Pages:

Extensive, comparable to factory service manuals (specific count not provided but implied to be comprehensive).

Type:

Service and Repair Manual Software

Language:

English

Digital Format:

PDF Download (Web-based access with one-year subscription)

📖 Manual Coverage

Engine:

Detailed diagnostics, repair procedures, timing, cooling, lubrication, fuel, ignition, emissions, and component overhauls.

Drivetrain:

Front-wheel drive (FWD) and all-wheel drive (AWD) systems, front and rear differentials, axles, driveshafts, and related components.

Transmission:

Automatic transmission (e.g., 4L65-E, 4L80-E) repair, overhaul, diagnostics, fluid services, and electronic controls.

Brakes:

Hydraulic system, ABS, traction control, brake pads, rotors, calipers, lines, and bleeding procedures.

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, ball joints, bushings, and alignment specifications.

Steering:

Power steering system, steering gear, steering column, tie rods, and power steering fluid.

Electrical:

Wiring diagrams, fuse box locations, battery, charging system, starting system, lighting, power accessories, and diagnostic trouble codes (DTCs).

HVAC:

Heating, ventilation, and air conditioning (HVAC) system diagnosis, refrigerant handling, compressor, condenser, evaporator, and climate control modules.

Body:

Body panels, doors, windows, locks, interior trim, bumpers, and external trim components.

Chassis:

Frame structure, chassis components, and related systems.

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, tire rotation, and general inspection procedures.

Troubleshooting:

Diagnostic flowcharts, common problem identification, and step-by-step troubleshooting guides for various systems.

Repair:

Component removal, installation, adjustment, rebuilding, and replacement procedures for all major systems.

Diagnostics:

On-board diagnostics (OBD-II) information, DTC interpretation, and use of diagnostic scan tools.

Specifications:

Torque specifications for critical fasteners, clearances, fluid capacities, electrical resistance values, and performance data.

Depth:

OE-level technical information, suitable for professional technicians and advanced DIY enthusiasts. Covers detailed component disassembly and reassembly.

📊 Manual Specifications

Format:

Digital PDF accessed via web browser.

Scalability:

Scalable vector graphics and high-resolution images for clear visibility on any device.

Access Method:

Web-based subscription with year-long access.

Digital Content Type:

Interactive digital content with searchable text and embedded diagrams.

⚙️ Engine Specifications

Engine Code:

LM7

Engine Type:

5.3L V8 OHV 16V Vortec 5300

Displacement:

5328 cc (325.1 cubic inches)

Bore X Stroke:

3.78 in x 3.62 in (96 mm x 92 mm)

Compression Ratio:

9.5:1

Horsepower:

285 hp @ 5200 rpm

Torque:

325 lb-ft @ 4000 rpm

Fuel Delivery:

Sequential Electronic Fuel Injection (SFI)

Fuel Type:

Unleaded gasoline, 87 octane (minimum)

ECU Model:

Delphi DRB-III (Diagnostic) / GM ECM

Coolant Type:

GM DEX-COOL (Orange)

Oil Type:

SAE 5W-30 Synthetic Blend or Full Synthetic

Oil Capacity:

6.0 quarts (5.7 liters) with filter

🔧 Transmission

Type:

4-speed automatic overdrive

Model Codes:

4L65-E

Features:

Electronic Transmission Control (ETC), Tow/Haul mode.

Fluid Type:

Dexron III/Mercon (or equivalent)

Capacity:

Approx. 11.7 quarts (11.1 liters) for the 4L65-E.

📐 Dimensions

Length:

219.3 inches (5570 mm)

Width:

78.5 inches (1994 mm)

Height:

76.7 inches (1948 mm)

Wheelbase:

130.0 inches (3302 mm)

Curb Weight:

Approx. 5,550 - 5,900 lbs (2517 - 2676 kg)

Gross Vehicle Weight Rating:

9,200 lbs (4173 kg)

Towing Capacity:

Up to 10,000 lbs (4536 kg) with proper equipment and configuration.

Cargo Volume Behind 3Rd Row:

Approx. 45.7 cu ft (1.3 cu m)

Cargo Volume Behind 2Nd Row:

Approx. 92.3 cu ft (2.6 cu m)

Cargo Volume Behind 1St Row:

Approx. 131.6 cu ft (3.7 cu m)

🛡️ Safety Features

NHTSA Rollover Resistance:

4/5 Stars (specific rating may vary slightly by configuration)

IIHS Frontal Offset Score:

Good (for 2000-2006 models tested)

ABS:

Standard Anti-lock Braking System (ABS) on all four wheels.

Traction Control:

Available Traction Control System (TCS).

Airbags:

Driver and front passenger airbags, available side-impact airbags.

Seatbelts:

Three-point seatbelts for all seating positions, front seat pretensioners.

💡 Technology Features

Audio System:

Standard AM/FM stereo with CD player, optional Bose premium audio system, available rear-seat entertainment system.

Parking Assist:

Available rear parking assist sensors.

Onstar:

Available OnStar safety and communication system.

🔧 Maintenance

Oil Change Interval:

Every 3,000-7,500 miles (5,000-12,000 km) or 6 months, depending on driving conditions and oil type used (refer to manual for specific recommendations).

Tire Rotation Interval:

Every 7,500 miles (12,000 km).

Transmission Fluid Service:

Check at every oil change; change approximately every 50,000-100,000 miles (80,000-160,000 km) or as per manual recommendations.

Coolant Flush Interval:

Initial flush at 5 years or 100,000 miles (160,000 km), then every 2 years or 50,000 miles (80,000 km) thereafter (using DEX-COOL).

Brake Fluid:

DOT 3 (GM P/N 12378476 or equivalent)

Power Steering Fluid:

Dexron III/Mercon ATF (GM P/N 12378515 or equivalent)

Differential Fluid Rear:

SAE 75W-90 Synthetic Gear Lubricant (GM P/N 10522777 or equivalent), with limited-slip additive if equipped.

Differential Fluid Front:

SAE 75W-90 Synthetic Gear Lubricant (GM P/N 10522777 or equivalent).

Common Problem 1:

Rear main seal leaks.

Common Problem 2:

Coolant leaks from intake manifold gaskets or heater core.

Common Problem 3:

Transmission solenoid issues or hard shifts in the 4L65-E.

Common Problem 4:

Front hub bearing failure.

Common Problem 5:

Dashboard cracking or warping due to sun exposure.

📚 Vehicle History

Manufacturer:

Chevrolet, a division of General Motors (GM).

Generation Timeline:

The 2004 Suburban is part of the GMT800 platform, which debuted in 1999 and represented a significant redesign with improved aerodynamics, interior, and safety features over the previous generation. This generation ran until 2006.

Assembly Locations:

Janesville, Wisconsin, USA; Silao, Mexico.

🏆 Awards & Recognition

Recognition Example:

The GMT800 platform vehicles, including the Suburban, were generally well-regarded for their capability and space, often appearing on 'best of' lists for large SUVs and trucks during their production run.