I currently own a '94 Ford F-250 Turbo IDI diesel. While I love the fact that the engine is strictly mechanical and and is a breeze to work on, the truck itself is rusting apart. So it's time for a replacement.

After doing some research, it seems like the Chevy Duramax (4x4 w/ allison tranny - personal use - I won't be pulling any outrageous loads) would be a terrific replacement vehicle and I have been looking into 2001-2004 models in my price range. I would appreciate your input into ownership and maintenance of these trucks.

-What are some maintenance items to watch out for?

-My biggest concern is with the injectors as they are expensive to replace (I can replace the entire set of injectors on my truck for $400!). Are all the injectors for the 2001-04 models destined to catastrophic failure?

Thank you for your assistance.

jct

JCT, here is a list of items from my '02 d/a with 199,000+ miles:

Brakes (of course) when they needed it
water seperator (change your filter!!!!!!!!!!!!!!) every 10,000
front wheel bearings @175,000
rear axle seals @168,000
front axle seals @195,000
Allison pump seal @195,000
transfer case rub @165,000
universal joints @185,000
carrirer bearing @ 185,000
upper & lower ball joints @185,000
inner and outer tie rod ends @ 185,000
pitman & idler arms @185,000
water pump (they all fail, its just a matter of when) @195,000
starter @ 195,000
fuel pressure regulator @185,000
injectors replaced @ 73,000
injectors soon to be replaced again before 200,000
steering wheel & seats @ 185,000 (this of course is optional)
regular fluid changes and grease jobs.

This may seem like a lot, but given the miles and condition of the vehicle, I figure after I get the injectos done here shortly it will be like a new truck again. Looks too like I need to update my sig, the miles are not even close. Hope this helps

my '02 has 105,000 on her. new MAF sensor at 70,000, new injectors at 74,000, pump rub upgrade installed before it happened last week.

Well they're nice to drive but hell to work on, engine wise you have to tear everything apart to alot of things mines got 114000 miles and front wheel bearings,2 sets of ball joints tie rods and so on transfer case rub kit installed and new injector pump,water pump so on seems like I drop 1500.00 a year for parts plus my labour like I say great driving truck rides like a dream handles -40 weather starting but takes awhile to warm up

Purchased a used DMAX in May 09.....57K miles....at 60K the Allison grenades....replaced under extended warranty. Too soon to tell, but everything else is working great. Regular service every 7,500 miles....Oh yeah, I have a clunking sound when taking off from a dead and when coming to a complete stop....I've heard there was a problem with the Driveline Yoke...

Basically the same thing as everybody else on here has listed as far as replacement stuff. I have 138,000 on mine as of now and I can't complain! Runs like new. Did the injectors at 122,000 and been runnin like a champ. Keep up on the regular maintenance and you should be fine.

Well they're nice to drive but hell to work on, engine wise you have to tear everything apart to alot of things mines got 114000 miles and front wheel bearings,2 sets of ball joints tie rods and so on transfer case rub kit installed and new injector pump,water pump so on seems like I drop 1500.00 a year for parts plus my labour like I say great driving truck rides like a dream handles -40 weather starting but takes awhile to warm up
what is a transfer case rub kit?

http://www.merchant-automotive.com/transfercasepumpupgradekit.aspx

just follow the above link to Eric's store