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Duramax First Generation: 2001-2004 (LB7) Discuss the first generation (2001-2004 LB7) of the 6.6L Duramax diesel engine & associated components. Engine related discussion ONLY.

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Old 01-07-2011, 11:24 PM   #1 (permalink)
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History of your lb7-items failed-items worn out!!

I am interested in LB7 owners listing failures and worn out had to be replaced parts on there LB7 daily drivers even if lifted/chipped etc. but no failures from the RACES at the strip or PULLING trucks. Please have a filled out signature..
Heres mine:

History:Truck used as daily driver for wife to and from work, has been lifted and chipped from day 1, has pulled a 13k toyhauler many a trips and I pull hard but do not abuse, but have pushed to limits, mostly synthetics and regularly serviced.

Failure: Front Wheel hubs-replaced ? 25k
Failure: Injectors-excessive injector knock-40k-replaced under warranty
Failure: Left Rear Wheel Seal- ? 80k
Worn: Idler, idler arm, pitman arm, upper left ball joint-90k(replaced and upgraded)
Failure:Injectors-excessive injector knock- 7yr 96k- dealer told me that injectors were bad but that they did not fail the specific leak test to be replaced under extended warranty @*&%@#@@, at 96k I was getting excessive injector knock and my coolant system has been overpressurizing for a while, I just last week replaced the injectors, resealed the cups and replaced the headgaskets.. upon inspection my headgaskets were marginal(not obviously blown but not in great shape in a couple spots) and a couple injector cups definitly looked to be the culprit(Probably from a shotty job of injector replacement at 40K by the dealer).

With the exception of the last failure that i think should have been fixed under warranty my truck has held up very well, I have not even had to change the brakes yet, but since my last failure and the high cost of the repair I would probably not keep another diesel out of warranty. Still love my Duramax though!!

Thanks, John
2004 LB7 Silver crew cab short bed 4x4
6" Pro-Comp lift
dual Fox racing shocks
35" BFG mud terrains on weld commando's
Magnaflow 4" exhaust
Stock air box w/K&N
Intake air horn mod
Rare Parts Extreme Tie rods, Moog problem solver idler/Pitman arm, Super Steer Extreme idler
Boost/Pyro gauges
DSP 5 EFI live ecm by Nick/Duramaxtuner
Air dog II Df-165 installed @96k
PPE boost valve

Last edited by AZHUNTER; 01-07-2011 at 11:33 PM.
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Old 01-08-2011, 07:12 AM   #2 (permalink)
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Injectors at about 40,000.
Front wheel bearings at about 120,000.
Rear wheel seals at about 120,000.
Clutch at about 135,000.
Injector pump at about 160,000.
Water pump at about 175,000
Injectors will be coming again soon.

2002 Silverado Ext. Cab, 4x4,ZF6 Trans,South Bend SMF,Diablo Sport Tuner, PPE Boost Valve, New FPR, Rear Gear goose neck hitch, 265/75/R16's. 167,000 miles
Brotherhood of Handshakers Member #177.
1998 Chevy 2500, 5spd Manual, 240,000 miles.
2003 Chevy Tahoe Z71.
1999 GMC 1500 Auto trans. 140,000 miles.(SOLD)
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Old 01-08-2011, 08:27 AM   #3 (permalink)
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Location: Thunder Bay On., Ca.
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Left rear wheel seal
Injectors approx 100,000 km
Right front wheel bearing 130,000 km
Rear brake rotors and pads twice due to rotors being eaten by rust 75,000/150,000 km
Emergency brake shoes due to rust, brake lining came off 150,000 km
Left front tie rod, backing over rock it bent like a pretzel 120,000 km
Injectors due for replacement 165,000 km
03 Chevy
EFI Live, turbo outlet down pipe, 4" front pipe, custom 4" exhaust, UNI intake filter, gauges, cool down timer, modded intake horn, removed intake resonator.

If it moves and shouldn't, use duct tape.

If it doesn't move and should, use WD40
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Old 01-08-2011, 09:25 AM   #4 (permalink)
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Both rear brake discs, axle seals, water pump and injectors last week, turbo this week And this truck is stock I do not race it, I love the duramax and I am able to do this work on my own but still very expensive, I have never owned a vehicle that cost this much to fix!
03 Silverado Allison Deep Trans w/ transynd, straight piped, Front Leveling kit.

Last edited by olivertractor; 01-08-2011 at 09:26 AM.
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Old 01-08-2011, 11:16 AM   #5 (permalink)
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Location: Tempe Az
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Injectors at 55k and now at 107k theyre failing again (just outside my 7 years )

70k. Inner and outer tie rod. Sheared it right out of the spindle, replaced the outer on the side of the mountain and then immediately bent the inner. Im assuming it was already weakened.

Upper and lower ball joints, both sides. Had been shot for a while 90k

Glow plug controller and all glow plugs. multiple trips to the dealer between 70-80k miles.

Idler and Pitmann Arms at 75k.

I think thats about it for now.
2003 2500HD. Crew Cab SB. LB7. 6" RCD lift, 35" Hancook tires on 18" Helo Wheels. Re-Keyed. Intake horn mod, Airaid Intake, IAH Delete, Banks Big Head Wastegate @ 27psi, 4" turbo back, no cat, straight piped exhaust. Nicktane filter adapter and CAT 2 micron filter setup. EFI Live. 452rwhp/840 ft lbs
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Old 01-08-2011, 04:52 PM   #6 (permalink)
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Computer Encoder Failure - 10,240 mi
L Rear Axle Seal - 25,181 mi
Rear Brake Shoe - 25,181 mi (due to axle seal failure)
Tailgate Cables - 48,760 mi (mfg recall)
ISS Replacement - 48,760 mi
Belt Tensioner Pulley & Surp Belt - 75,600 mi
ISS Replacement - 95,993 mi
Jounce Bumpers, Pitman Arm, Idler Arm - 135,000 mi
Injectors - 135,005 mi
Shocks, Bil 5100 Series - 153,500 mi
Brake Rotors, Brake Pads - 153,816 mi
RF Wheel Bearing/Hub - 154,900 mi
Fuel Sending Unit - 166,200
Hydroboost - 169,985 mi
Pump Rub Kit (Kennedy Kit) - 172,800 mi
Surp Belt, Tensioner, 2 Idler Pulleys - 174,300 mi
1 Injector Bad Now - 174,500 mi
03 Chevy 2500HD 4x4, LB7 D/A, Michelin 245AT's, Swiss Cheesed w/ACDelco Air Filter, Nictane Fuel Filter, Edge W/Attitude, Bilstein Shocks, AirRide Springs, Rino Liner, Pullrite Superglide Hitch, TTT Mirrors, Flowmaster Muffler,http://dmaxstore.com/
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Old 01-08-2011, 05:16 PM   #7 (permalink)
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Location: Mid-Michigan
Posts: 23,034
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Previous to my ownership: https://www.dieselplace.com/forum/sho...1&postcount=13
I had to replace the Tcase shortly after I got it home, due to poor work done in Texas.

Two new batteries
brakes on all 4 wheels
rear axle seals
coolant temp sensor
pinion seal
front suspension bumpers

and yes, due to racing and pulling, had to rebuild the engine last year. That necessitated new injectors. None of that was the fault of the truck itself. Trans was redone by Merchant in 2007.

Truck could use new front hubs, the batteries could use replacing again, and racing has worn the brakes again. Really should replace the drivers side seat cushion and buttheater, and the carpet is past the point of cleaning.

Overall, I have really enjoyed my truck for the past 5-1/2 years and 75,000+ miles

"BBT" -- 2003 GMC 2500HD CC/SB 4x4 - 12.14 @ 111.15
"Kleshay" -- 2000 C5 Corvette -- the toy
"The Cruzer" -- 2014 Chevy Cruze Diesel -- the DD

Marlene (Molly) Bacon -- 1936 - 2019 -- RIP Mom
You're missed both at home and on the piano

Success is getting what you want. Happiness is wanting what you get.
Reality is a matter of perspective.

Last edited by TheBac; 01-08-2011 at 05:17 PM.
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Old 01-08-2011, 09:24 PM   #8 (permalink)
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50k replace factory tires with 285's
89k replace bridgestone dueller tires with 295's
89k u joints
89k transmission adapter houseing (from bad ujoints)
89k replace starter(i broke it doing above stated work)
110k idler/pitman arms and ball joints
115k new batteries
125k front brake pads
135k 4 new rotors
135k new brake pads all around
135k drivers side wheel bearing
135k 4 new shocks
140k ujoints again
140k 1 abs sensor(was on the new hub side)
145k needs new gauge cluster(not fixed yet)
150kish started randomlly smokeing at idle

Mileage may be off some from oversize tires since 50k and gauge cluster randomlly working for last year.
2011 chevy crew cab D/A 4x4 stock for awhile

2003 chevy ext cab D/A 4x4 with 258,000 ish miles with original injectors . Sold a 20mpg truck for a 15mpg truck

Last edited by sleadhead; 01-08-2011 at 09:33 PM. Reason: added
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Old 01-09-2011, 12:22 AM   #9 (permalink)
Gear Grinder
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I have 115K on my 2002. long list.....

Air intake heater circuit. Thats it. I must have got a good one.
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Old 01-09-2011, 12:33 AM   #10 (permalink)
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Location: On my way to Canada
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Purchased the pickup with 89k miles, had a dealership look up whats been to it.
Before I bought it,
39k - Injectors were replaced under warranty and other misc. small recall items.
After I bought it,
90k - New gauge cluster stepper motors
91k - 8 new injectors and return lines
91k - 2 new batteries
92k - New lower/upper ball joints, pitman/idler arm
front passenger side wheel bearing needs to be replaced, starting to get some slop in it.

Parts I've installed to try and prevent future failure, or at least help I hope so.
2 Kennedy lift pumps
fuel pickup mod
Kennedy mega filter
Cognito upper A arms
Cognito pitman/idler arm brackets
pump rub kit that I haven't installed yet

I find it funny that TheBac hasn't had to replace that much stuff. Engine related items, especially injectors, looks like hammering down the skinny pedal has it's benefits.

I like how I've had to replace alot of things(expensive too) after I bought the damn thing.
I love the pickup but the 2500HD 6.0 I had before was cheaper to maintain, but doesn't have near the power!!!


2003 LB7 White Dually

Pyro and Boost Gauge
Home made intake
Dual Kennedy lift pumps and Mega filter
EFI Live (dsp5 to install)
Bully Dog 4in SS exhaust
1st set of injectors, 37k, 2nd at 90k

Future Hopes
Install homemade dsp5 switch
Compound Twin Turbos
Built Tranny
Profab manifold with up pipes
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