It all started at 10,000 miles when the transmission went out when I was on the road. It was in and out of the shop with tranny problems up until about 50,000 miles. On more than one occasion they called me to come pick it up and before I got off the dealerships property, it would go out. They finally decided to put a new one in it and It continued to have problems for about the next 3 months. After they finally got that problem fixed, my injectors went out. They have gone out twice in the last 2 yrs. I also replaced the water pump about 3 months ago. The heater coil needs to be re-insulted, so until I drop $600 on that, it will just continue to rattle and bug the hell out of me. The idler arm in the steering is bad and needs to be fixed. Now, my truck is in the shop with a hole in the transfer case. It also needs a slip yoke. Im lookin at $2200 to get that fixed. It also needs a new master cylinder and possibly a pump that will run around $1500. I plopped down $40000 in 01 cause I wanted a truck I could 200,000 out of with minimal maintenance. What I've got is truck that's been in the shop for about 4 months since Ive owned it and It needs about $5000 in repairs to fix everything right now. Oh, I forgot, the U joints werre replaced about a yr ago. This thing is really eating into my pocket and Im tired of it. A truck of this magnitude isnt supposed to fall apart like this 113,000 miles. Funny thing is, everytime I pull into a Chevrolet service department, the mechanics cant believe that they've actually got a Dmax to work on. When I tell them what a lemon it is, they look at me as if Im lying about it. Everything that has gone wrong with my truck they tell me how they've only had about 1 or 2 cases other than mine. Does anyone have any suggestions on what I can do? Can I sew Chevrolet or Allison? Thanks

Wow, sorry to hear about all your troubles! Have you tried talking to a regional service rep. or call GM up and relay your dissatisfaction?

I tried to contact Chevrolet a few yrs ago and they would never respond to me. Honestly, I wouldn't even know who to call. I bought the truck in East TX, and now live in Atlanta. The dealership where I bought was going to sell many any truck I wanted at cost a few years back, but I had mine paid for and didn't want payments. So, I guess my problem is that I just dont know how to contact the right people.

Injectors are a common problem, and unless your dealer lied to you, they are covered under warranty to 200,000mi.

Allison failures with stock HP trucks are actually very rare. Many Allisons on stock trucks have went over 200,000. When you use a power adder, failure will happen alot sooner.

First heater coil failure I've heard of.

Idler and pittman arms are wear components, running big tires will accelerate wear. This is true for most vehicles.

Hole in the transfer case? If it was caused by road debris, your auto insurance will normally cover it.

Master cylinder failure is also rare.

Water pump is common, GM needs to rethink that.

Lemon law covers newer vehicles that can't be fixed after multiple tries.

Sorry you had troubles with your truck, but there is not a brand out there that there is not similiar problems with in isolated incidents. You got an "unlucky" truck. If I were you, I'd sell it. I had a Nissan truck with a similiar history that I had to dump.

They covered the injectors under warranty. Im hearing the hole in the transfer case has been a problem for a few people. The pump in the transfer case is shaking loose and vibrating against the case enough to wear a hole. I went in yesterday and looked at the hole and it is about half the size of a pencil erasor.

Anyone else have any ideas on what steps I could take to get a little justice?

I have to agree with McRat. Some of your problems are normal wear, like the idler and pittman arms. The tranny they fixed, even if it took a few times, but you said it now is fixed. Injectors, we're on our second engine due to them, and it's on it's second set. We expected this after reading this forum.

The transfer case, that sucks, but parts wear and break. In most states, the lemon law is only valid for the first year, some the frist two. You are going on your 6th year. If you aren't happy with the truck, sell it. I don't see a case to sue (not sew, that involves thread ;)).

I think Eric has a fix for the transfer case?