Maintenance Costs For A 2004 Cargo Van

[Moot]

Listed below are the costs for maintaining a 2004 Chevrolet 3500, long wheelbase 6.0 V-8 slop bucket, for the first 500,000 miles as it came from the factory. The costs do not include the installation or maintenance of extras such as a bed, insulation, flooring, radios, house batteries etc. It also does not include any towing fees.

Oil, filter and lube: 107 @ $1866. All performed by myself, no labor costs.

Tune-up: 5 @ $2667. 1st tune-up included ignition wires from NAPA that were guaranteed for life and replaced for free at following tune-ups. 2 differential lube changes were included in tune-ups at 200,000 and 400,000 miles. Other minor repairs were included as was labor.

Tires: 18 @ $3100 includes alignments.

Batteries: 3 @ $476

Front wheel bearings: 4 @ $1570 240,000 & 432,000 miles.

Alternators: 6 @ $1332. The original 105 amp was replaced at 262,000 miles. That replacement lasted 1 week. Some alternators were replaced free of charge. Some only labor. The last 2 alternators were 155 amps from NAPA with a lifetime warranty excluding labor.

Radiator flush: 4 @ $375

Transmission fluid and filters: 2 @ $320

Air Filters: 7 @ $152

Brakes: Front pads and rotors, $450 changed at 377,000 miles. Still running original rear pads and rotors.

Shocks: Front and rear shocks, front springs @ $715. 377,000 miles.
Replaced all 4 shocks @ 556,755 mi. Life time warranty. $125 for labor which included mounting 2 new tires and rotation.

Deer collision: replace pass. side headlight and turn signal light assembly and grill. $950

Misc Repairs:
-replace sway bar and brake caliper mount. $400.
-replace T.P. sensor. $132
-replace upper coolant hose. $248
-replace 3 windshields $300. (Panther windshield plan, pay 1st $100)
-replace A.C. tensioner and belt. $201
-differential lube change 2 included in tune-up cost.
-lights, wiper blades misc. parts. $747

Front End: Both upper ball joints, pitman arm, idler arm and alignment $916 @ 516,000 miles

Oil Cooler Gasket: Replace oil cooler gasket, inlet pick-up O-ring and oil pan gasket. $502 @ 544,000

U-Joints: Replaceall u-joints (3) and replace rear transmission seal.Also replaced TPS (warranty) and cleaned throttle body. $391 @ 567,000



Total: $17,755 or .03/mile.


Random thoughts:

factory DexCool was replaced with good old green stuff and oil changed within the first 1000 miles.

van came from factory with front end alignment out of spec. Replaced original steer tires at 60,000 mi.

thinking about replacing all original coolant hoses and water pump.

 

[scottm4211]

Slop buckets rule.

Do you always use the same oil? Are you using any between changes?

 

[Jack_Berry]

i think after 8 years replacing the hoses might be a real good idea.

 

[Moot]

Slop buckets rule.

Do you always use the same oil? Are you using any between changes?

Regular Valvoline 5w-30 oil and so far no make up oil between changes.

 

[purgoose10]

Moot, How many miles are you going to run that van for? When do you plan on replacing?
One of mine is a 2002 which I have for sale. I have replaced about everything you have plus A/C, Condenser, Radiator. Everything from the front of the engine to the bumper.
Looks close to my schedule. I am running a 6.5 diesel in the 02 and in my 10 model I'm running a 6.0. 80K on the 10 and doing pretty well maintenance wise.

 

[LDB]

I've got mine figured at 2cpm immediate and 2cpm future meaning 2cpm for oil changes, lube and other shorter term and 2cpm to accumulate for water pumps, tires and other longer term things.

 

[scottm4211]

I'm just under 300k on my 06 with original alternator. Don't know if I'm rolling the dice as most seem to go through them pretty quick.

 

[Moot]

Moot, How many miles are you going to run that van for? When do you plan on replacing?

I'm not sure. I dumped my 1998 at 375,000 miles and probably should have kept it another couple of years. I have been mentally building some type of cube van for years, so maybe this fall?

 

[scottm4211]

I'm not sure. I dumped my 1998 at 375,000 miles and probably should have kept it another couple of years. I have been mentally building some type of cube van for years, so maybe this fall?

Are you still getting the same fuel economy at 500k?

 

[Moot]

Yearly mpg:

2004 15.89
2005 16.50
2006 16.39
2007 16.29
2008 16.54
2009 17.07
2010 16.94
2011 16.85

The last couple of years I have reduced my freeway cruising speed from 67 mph to 63 mph.

 

[zero3nine]

Yearly mpg:

2004 15.89
2005 16.50
2006 16.39
2007 16.29
2008 16.54
2009 17.07
2010 16.94

The last couple of years I have reduced my freeway cruising speed from 67 mph to 63 mph.

Mileage numbers look about the same as mine. I find if I have the time, and the willpower permitting, if I can run between 55-60mph, I can get up to 19mpg fully loaded.

 

[purgoose10]

I'm not sure. I dumped my 1998 at 375,000 miles and probably should have kept it another couple of years. I have been mentally building some type of cube van for years, so maybe this fall?

I bought my 02 from a couple who had it parked in their back yard for several years and hardly used it. They were retired and when the weather was nice they did some expediting. They did it to pass the time.
I have a 10 model also with a 6.0/3.73 with a driver on it. It's averaging about 16.5 all miles, load/empty.
I am replacing the 02 with a Cargo max and probably going thru what you are trying to figure out what exactly I want. I'm also not in a hurry since gas prices are taking over again.
Thanks for the info. Happy V'ng.

 

[Moot]

Maintenance Update:

Today I had the front end rebuilt. Replaced both upper ball joints, pitman arm, idler arm and alignment. Parts, labor and tax $915.90

 

[scottm4211]

Maintenance Update:

Today I had the front end rebuilt. Replaced both upper ball joints, pitman arm, idler arm and alignment. Parts, labor and tax $884.81

What was the front end feeling like that made you do the rebuild?

 

[Moot]

Yes it was!

 

[scottm4211]

Lemme think about that...

 

[Moot]

Don't think too hard! I misunderstood your post. The front tires were beginning to scallop on the inside edges. The last time I had the van aligned it could not be brought to spec because of wear so I knew this day was coming. Also the front end and steering felt a bit loose and sloppy. Of course wear like this occurs over a long period of time and isn't that obvious. Driving it home last night it felt like a new van. I may keep it for another 500,000 miles. I just hope this isn't the beginning of nickle, dime, C note, grand stuff.

 

[purgoose10]

What was the front end feeling like that made you do the rebuild?

On one of my Chevy Extended, when the steering wheel shook when hitting a bump and hearing the front end make noises when going slow. The shimming is the idler arm, usually the first to go. After owning many Chevy vans I recommend changing out the front wheel bearings between 200,000 and 225,000 miles just to be safe. They seem to go about then. Front end depends mostly on what part of the country you mostly run.

Also ad everything that Moot said in his post.

 

[aileron]

Moot, I started another thread about my 2004 Sprinter maintenance cost here. I also included my fuel stats. I would like to see your fuel figures also, for a rough comparison between a gasser and a diesel van. Do you have this info?

 

[Moot]

2004 15.89 mpg, ppg $1.76, ppm .11

2005 16.50 mpg, ppg $2.16, ppm .13

2006 16.39 mpg, ppg $2.42, ppm .15

2007 16.29 mpg, ppg $2.70, ppm .17

2008 16.54 mpg, ppg $3.08, ppm .19

2009 17.07 mpg, ppg $2.24, ppm .13

2010 16.94 mpg, ppg $2.67, ppm .16

2011 16.86 mpg, ppg $3.37, ppm .20

The last couple of years I have reduced my freeway cruising speed from 67 mph to 63 mph.