2001 GMC K2500 General Maintenance

[kevm14]

Yes, this is what I meant by scour eBay. Although scouring for me amounted to searching for the p/n and clicking the first thing that came up.

Anyway, that listing allows up to qty 3 to be purchased. Maybe it was 4 before you bought yours?

[rpaoness]

I had looked by every pn permutation, but likely stopped at the $400 mark thinking that was too high. Unavailability has changed my perception of too expensive.

[rpaoness]

I got a shipping confirmation number with R&L carriers, so I think it's actually on it's way. Says it's coming out of TN, which matches where I thought these guys were based out of. I tried looking them up outside of ebay to see if the listing was cheaper on their own website, but couldn't find the bumper there at all.

[rpaoness]

On the oil cooler front - looks like the housing-to-housing gasket was originally a metal gasket and no longer available - oil cooler replacement required if it leaks...

https://www.merchant-automotive.com/Oil ... -2001-2010

https://youtu.be/biUOKZ8oY5g

[rpaoness]

Finally got oil cooler out, regasketed (just cooler-to-block oil and coolant) and reinstalled. I don't know yet if it fixed what I perceived as an oil leak. My current theory, if it stays somewhat leak-free going forward, is that the thick rubber style gasket between the cooler coolant outlet to the block had hardened and was weeping/leaking. The coolant leaking displaced oil stuck in the transmission bellhousing or elsewhere and made it look like an oily mess leak. I had about 3 qts of makeup coolant needed in November with no apparent leak and none added since, so I believe it is possible that it was weeping. Years ago I had a random coolant leak from the drivers rear of the block that went away, so I'm guessing it was the same gasket having an issue then, but then later stopped.

Replacing the oil cooler gaskets wouldn't have been too bad if it weren't for the o-ring on the end of the water pump pipe. It's a relatively thin cross section o-ring and there are a lot of awkward angles shoving the oil cooler back on to the end of the pipe. 3 times I managed to roll and pinch the o-ring, which you can't see until loading coolant. I dumped two gallons in before I noted that it was spilling out on the ground the first time, then about 2 qts while watching for it, and another 1qt the 3rd time. I finally went and bought a second o-ring, dried everything really well, cleaned the somewhat-rough inlet to the oil cooler really well, and then got it to slide together. This required cooler removal/reinstall 4 times. This was also a new water crossover pipe since I had noted significant rust when I did the exhaust manifold.

Got the new bumper on - went well and looks better.

I'm debating whether I go after the super-minor-weep on the transfer case outlet seal - I bought a new one but haven't installed yet. I probably will, and inspect the rear u-joint while I have the driveshaft off.

We'll see if it still leaks after I drive it some.

[kevm14]

I'm tempted to blame some of this stuff on how much sitting that truck does. But it is what it is. And yes it's old which is certainly a factor as well.

Additionally, you are paying the diesel tax in maintenance/complexity.

[rpaoness]

Idk - the box truck was a similar level of restoration, but I guess service was easier due to the cabover/engine doghouse?

Parts were cheaper I guess.

I find most of my recent struggle is corrosion of engine components from it being a plow truck/out every storm. Sometimes I wonder if I should've ponied-up the $'s for a lower mileage southern drivetrain while I was in Hicksville OH.

[rpaoness]

Still leaked after the oil cooler/adapter removal, reseal, and reinstall. The oil leak was the oil cooler feed line banjo bolt sealing washer leaking under the turbo. I have typically had really good luck w/ banjo bolts and no leaks, but this one I think I was worried about disturbing the old washer on the block since I can't really clean the surface of the block under the turbo well. I think I left the old washer and attempted to reuse it. Since they're steel and not copper on this old of a Duramax, that was a bad idea I guess. I ordered two copper sets that are listed as applicable to 2004-20XX per GM, but listed as '01-on on aftermarket websites.

97331137

https://www.amazon.com/ACDelco-97331137 ... QIR0&psc=1

[rpaoness]

I lied again - I thought it was the washer based on the oil puddling on the lifter valley V. Turns out it was the Gates line weeping somewhere in the stainless braid and goobering down to the fitting. Took reinstalling and letting it idle for 10 minutes for it to start goobering again, and then I saw it coming off the line instead of the fitting. Ordered a warranty replacement line from RockAuto. Hopefully it gets here before I need the truck mid next week, otherwise I'll have to see if any dealers stock them. Looks like NAPA stocks one in Middletown and O'Reilly's can get one next-day.