Engine Mechanical:
All gasoline and diesel engine components, including disassembly, assembly, inspection, and repair.
Engine Electrical:
Ignition system, fuel injection system, starting and charging system, engine control module (ECM) diagnostics.
Transmission:
Automatic (4L80-E, 4L85-E) and manual (NV4500, NV5600) transmission service, overhaul, and diagnostics.
Drivetrain:
Front and rear axle service, driveshafts, universal joints, differential service, transfer case (if applicable).
Suspension:
Front and rear suspension component inspection, replacement, alignment procedures, and troubleshooting.
Steering:
Power steering system service, steering gear inspection and repair, steering column components.
Brakes:
Hydraulic brake system, ABS system diagnostics, brake pad/shoe replacement, rotor machining/replacement, brake line service.
Electrical System:
Complete wiring diagrams, lighting systems, instrument cluster, power windows, door locks, remote keyless entry.
HVAC:
Heating, ventilation, and air conditioning system diagnostics, component replacement, refrigerant handling and charging.
Body And Frame:
Body panel repair, interior trim removal/installation, door mechanisms, tailgate, glass replacement.
Chassis And Frame:
Frame inspection, repairs, and corrosion protection.
Scheduled Maintenance:
Detailed maintenance schedules for oil changes, filter replacements, fluid checks, and component inspections.
Troubleshooting Diagnostics:
Systematic diagnostic procedures and flowcharts for identifying and resolving common and complex issues.
Component Replacement:
Step-by-step instructions for replacing virtually all serviceable components.
Engine Rebuild:
Comprehensive procedures for engine disassembly, cleaning, inspection, machining, and reassembly.
Transmission Overhaul:
Detailed instructions for complete transmission disassembly, component replacement, and reassembly.
Brake System Repair:
Procedures for bleeding brake systems, replacing brake lines, calipers, and master cylinders.
Electrical Diagnostics:
Using multimeter, oscilloscope, and scan tools to diagnose electrical circuits and systems.
HVAC Service:
Refrigerant recovery and recharging, leak detection, and component testing.
Diagnostic Tools:
Information on using GM's Tech 2 scan tool (or equivalent) for advanced diagnostics and module programming.
Torque Specifications:
Precise torque specifications for all critical fasteners and engine components.
Clearances Tolerances:
Detailed specifications for component clearances and wear tolerances for proper engine and driveline function.
Wiring Diagrams:
Comprehensive, high-resolution wiring schematics for all vehicle electrical systems.
Special Tools:
Identification and usage instructions for specialized tools required for specific repair procedures.
Engine Options:
6.0L V8 Power Stroke Turbo Diesel, 8.1L V8 Vortec Big Block Gasoline
6.0L Power Stroke Horsepower:
300 hp @ 3300 rpm (approx.)
6.0L Power Stroke Torque:
520-540 lb-ft @ 1600 rpm (approx.)
8.1L Vortec Horsepower:
325 hp @ 4000 rpm (approx.)
8.1L Vortec Torque:
455 lb-ft @ 3200 rpm (approx.)
6.0L Power Stroke Fuel System:
High-pressure common rail (HPCR) direct injection
8.1L Vortec Fuel System:
Multi-point fuel injection (MPFI)
Fuel Type:
Diesel (6.0L), Unleaded Gasoline (8.1L)
Transmission Options:
Allison 1000 5-speed Automatic (Diesel), NV4500 5-speed Manual (Gas/Diesel), NV5600 6-speed Manual (Diesel)
Optional Transmission:
N/A (listed are the available, not strictly optional in all configurations)
Allison 1000 Features:
Heavy-duty design, electronic control, Tow/Haul mode.
Manual Transmission Features:
Robust construction for heavy loads.
Wheelbase Options:
130.0 inches (Regular Cab), 143.5 inches (Extended Cab), 153.0 inches (Crew Cab)
Overall Length:
Varies by cab and bed configuration (e.g., 237.4 inches for a 4WD CC Long Bed)
Bed Length Options:
8.0 ft (96 inches), 8.25 ft (99 inches - Long Bed)
Curb Weight:
Approximately 6,000 - 7,500 lbs (varies significantly by configuration and engine)
Gvwr:
Up to 11,400 lbs (for 3500 models)
Max Payload:
Approximately 4,000 - 5,000 lbs (varies by configuration)
Max Towing Capacity:
Up to 13,000 lbs (conventional hitch), up to 16,000 lbs (gooseneck/5th wheel hitch)
NHTSA Front Crash Rating:
4/5 stars (for most models of this era)
IIHS Small Overlap Front Rating:
Not applicable to this era/vehicle type.
ABS:
Standard Anti-lock Braking System
Traction Control:
Available StabiliTrak (on some models/configurations)
Airbags:
Driver and front passenger airbags
Seat Belts:
Three-point seat belts with pretensioners
Oil Change Interval:
Gasoline: 5,000-7,500 miles or 6-12 months. Diesel: 5,000-10,000 miles or 6-12 months (severe use may require more frequent changes).
Filter Replacement:
Engine oil filter, fuel filter (diesel), air filter at recommended intervals.
Transmission Fluid Service:
Automatic: 50,000-100,000 miles depending on usage. Manual: Inspect as needed, fluid changes typically longer intervals.
Engine Oil Gasoline:
API SN/SP, SAE 5W-30 (check owner's manual for specific viscosity)
Engine Oil Diesel:
API CJ-4/CK-4, SAE 15W-40 (check owner's manual for specific viscosity and specifications)
Coolant:
GM DEX-COOL (Orange) Extended Life Coolant or equivalent meeting GM6277M
Transmission Fluid Auto:
GM DEXRON-VI Automatic Transmission Fluid (ATF)
Transmission Fluid Manual:
GL-4 or GL-5 Gear Oil (specific viscosity depends on transmission model, consult manual)
Brake Fluid:
DOT 3 or DOT 4 Hydraulic Brake Fluid
6.0L Power Stroke Common Issues:
EGR cooler failures, turbocharger issues (sticking vanes), injector problems, head gasket failures.
8.1L Vortec Common Issues:
Intake manifold gasket leaks, valve cover gasket leaks, potential for oil consumption.
Transfer Case Issues:
Variable speed sensor failures, pump failures in NV246 (Autotrac) models.
Electrical Gremlins:
Grounding issues, corroded connectors leading to intermittent electrical problems.
Chevrolet Truck Legacy:
Chevrolet has a long history of producing robust and reliable trucks, dating back to the early 20th century.
Silverado 3500 Evolution:
The Silverado 3500 has evolved from earlier heavy-duty C/K series trucks, consistently offering increased payload and towing capabilities.
Production Years Gmt800:
1999-2007 (GMT800 platform)
Manufacturing Locations:
Primary assembly plants in North America (e.g., Fort Wayne, Indiana; Silao, Mexico).