[fats]

1. Ok I had the nsbu switch failure.
2. The leaking brass plug in the left hand head.
3. I believe I've isolated the bearing squeak to the idler on the belt as the pulley now has a burnt side.
I only have 25,000 on this unit. What will be my future failures so I can do some preventative maintanence?

 

[ockgator]

None to worry about, I've got 62K and had only the leaky plug on the head.

Sometimes the belts get a "glaze" on them which is the squeal. Easy way to tell is to pour some sand on belt(engine off) then fire it up, no sand will get into engine unless you leave air filter off.

 

[Duromax04]

Those seem to be pretty minor issues to me. Granted, you hope for no issues, but considering what some of the diesel boys have had, you have been lucky. I have had the leak in the plug, easy fix, and I have a squeaky belt, but it has been replaced once, so it must not be that belt. The squeak stops after a little bit. Other than that, I really like that truck. Runs great.

 

[biggwing]

I have had all those and the only other things to look out for that nailed me were the Crank Position Sensor and the front main seal both went out. I also had the Allison trans explode, but that appears to be an isolate incident. All these happened before 32,000 miles. I am now over 40,000 with no additional problems....Yea!!!!! You also have to remember that I live in Alaska, work a huge plow on the front of my truck, and overall beat the living daylights out of my truck on a daily basis. I understand the frustration, but I think you are through the worst of it and there are a lot of other manufacturers having much worse stuff with their vehicles out there. Hang in there.....

 

[mikek996]

second the crank sensor

 

[viabill]

I only have 25,000 on this unit. What will be my future failures so I can do some preventative maintanence?

Here's the tally on my '01 8100 2500HD 4x4 with 85K miles, now.
Under warranty
Cam position sensor
Coolant plug in head
belts/idlers (squeaky efery fall, so I had the dealer replace)

Out of warranty
Battery- terminal broke seal and leaked acid on the w/s washer pump & trashed it.
W/s Washer pump- see above.
Crank position sensor
Water pump
Fuel sender
Fuel pump (is about to go... noisy)

Potential failures: transfer case... known flaw wears hole in the case and leaks fluid out. $2K + to fix.

All in all, that's not too bad for maintenance expense over 6 years. The only one of these problems that bothers me is the transfer case issue. Of course, it hasn't failed, yet, so I can't complain but if/when it does, I'll be mighty pissed if GM doesn't kick in for the repair since it's a design flaw. That would send me to the competition for my next truck.

 

[ABQFirefighter]

Already replaced:
- Crank Position Sensor
- NSBU switch
- Pitman and Idler arm
- 2-piece driveshaft replaced with one-piece aluminum.

Getting ready to replace this weekend:
- Driver's side hub
- Pitman and idler arm (second time, but this time w/ Cognito kit)

Still needs replaced:
- Fuel pump/sender (noisy and erratic reading)
- Washer fluid reservoir leaks from somewhere.....

Just started leaking oil from a line on the driver's side of engine.

Not too sure about this coolant plug thing (First time I've heard about it).

 

[ockgator]

L head just above exhaust manifold,uses 3/8 drive to tighten it, just like rear end fill plug. If it leaks you'll not only smell it but the dex cool will leave a whitish trail.

 

[rcpd34]

Crank sensor and Intermediate shaft.

Still a great truck that either sits or gets worked to death.