2004 G3500 Box Truck 271k Service

[rpaoness]

Box Truck Up for annual maintenance. "assembled" the truck at about 268k mi a year ago, and it's time for the first major maintenance evolution since.

- Oil Change - ordered filter/oil a while ago.
- Transmission fluid/filter - filter ordered today
- Oil cooler adapter line bolt thread helicoil install to eliminate gasket leak (one went in "poorly" a year ago) - helicoil (M6x1.0) and gasket ordered today
- Starter replacement (working, installed starter sounds weak/bad) - starter has been in the back of the truck for 6+ mo, I should just install
- Grease front end

I think that's about it.

[rpaoness]

So far:
- I managed to install a helicoil in the M6x1.0 hole that holds the oil cooler adapter on and reinstalled/retorqued. Hopefully it never leaks again.
- changed oil and filter
- changed transmission fluid - I think only like 3.5 qts came out. That seems like relatively little. Hopefully it wasn't low. I don't see any evidence of leaks.

Still need to swap the starter.

[rpaoness]

I think more than 1.5 qts was still hiding in the pan, so 5 qts out is about normal I think.

Finished starter swap and greasing. Starter sounds way better and solid, but I don’t think it’s really cranking faster. Oh well.

[rpaoness]

I had pulled the negative terminal for the starter change. Had ABS and brake light during the first or second start after reconnecting. Went away again after cycling the key. Hopefully that’s not something new starting.

[kevm14]

Does that have Stabilitrack?

[rpaoness]

Idk

[kevm14]

It might be too old for that. But if it does it could need the steering wheel run to the left and right after a battery disconnect to "calibrate" the steering angle and yaw sensor. If it didn't say anything like this in the cluster then this is probably not it.

[rpaoness]

Appears to have used about 2/3 of a quart in 600 mi - level was a little low with "just" 5 qts at oil change, was at the low mark on return from a VT round-trip. Oil change was 5 qts of Kirkland (costco) full synthetic 5W30, added a quart of M1 5W30 I had on hand.

[kevm14]

Internet says 6 quarts. Why would you do 5?

[rpaoness]

Level was about 2/3 of the way up the stick from add to full. I didn’t want to drive to get more oil and we had just had a conversation about not mixing.