REAL MAN TRUCKWORKS & SURVIVAL

VEHICLES, CAMPERS, and BOATS => General Vehicle Related Discussion => Topic started by: dave945 on November 02, 2021, 08:43:59 PM

Title: 2004 Chevrolet Express 2500
Post by: dave945 on November 02, 2021, 08:43:59 PM
Okay, so you may recall this van just surpassed 500,000 miles. We’ve been looking for a replacement for it for a while, but the selection is slim and what is out there is way overpriced as far as I’m concerned. Which got me to thinking, “what if I just took some time/money and got the engine cleaned up and rebuilt, along with any other things wrong with the van. I could get the seats reupholstered, carpeting or flooring put in, go through the suspension/steering components and redo the sound system and probably come out ahead of the game and have a van that should be solid for the next couple hundred thousand miles.”

What do you think?  I’m not sure what the rebuild/cleanup would entail at this point, just throwing some thoughts around.


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Title: Re: 2004 Chevrolet Express 2500
Post by: stlaser on November 02, 2021, 09:44:53 PM
$10-$20k depending on what exactly you redo unless you’re doing it yourself then obviously just parts.
Title: Re: 2004 Chevrolet Express 2500
Post by: rpar86 on November 02, 2021, 10:31:06 PM
Don may have a 6.0 for it soon… ;)
Title: Re: 2004 Chevrolet Express 2500
Post by: TexasRedNeck on November 02, 2021, 10:32:49 PM
$3k. Get a motor from a wrecking yard


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Title: Re: 2004 Chevrolet Express 2500
Post by: Bob Smith on November 02, 2021, 10:52:10 PM
I would think it would mostly depend on “ if you need something on the road or if it could be down while refreshing”. If looking at replacing with used then most likely better to rebuild what you have.
Title: Re: 2004 Chevrolet Express 2500
Post by: dave945 on November 02, 2021, 11:19:44 PM
Don may have a 6.0 for it soon… ;)
I did think of that. But I’ll wait until he finishes shaking it down. That would make for a sweet riding people mover. :)


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Title: Re: 2004 Chevrolet Express 2500
Post by: KensAuto on November 03, 2021, 11:47:56 AM
Does everything have 500k? Transmission, diff, front end, sensors, HVAC system, etc. ?

If it has to be reliable, those are things that can potentially, scratch that, Will cause you to chase your tail unless done at the same time.
Title: Re: 2004 Chevrolet Express 2500
Post by: dave945 on November 03, 2021, 05:57:28 PM
Does everything have 500k? Transmission, diff, front end, sensors, HVAC system, etc. ?

If it has to be reliable, those are things that can potentially, scratch that, Will cause you to chase your tail unless done at the same time.
Pretty much everything is original. Haven’t had to do too much with it. I see what you’re getting at, either do a full refresh or suffer the consequences of having 17 year 500k Mike’s old parts that will continue to age further.

So pick up a 6.0 w/4l80e from the junk yard, refresh/rebuild both.  Then pull old engine, refresh everything still on the chassis (brakes, suspension, differentials, steering, interior). Then drop in new engine/transmission, get it all buttons up and then drive it like I stole it.


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Title: Re: 2004 Chevrolet Express 2500
Post by: TexasRedNeck on November 03, 2021, 06:27:45 PM
Sounds like a plan


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Title: Re: 2004 Chevrolet Express 2500
Post by: KensAuto on November 03, 2021, 07:34:50 PM
Absolutely.
Or play the lottery.
Title: Re: 2004 Chevrolet Express 2500
Post by: stlaser on November 03, 2021, 08:09:36 PM
$10-$20k depending on what exactly you redo unless you’re doing it yourself then obviously just parts.

So we’re back to what I said eh?  :popcorn:
Title: Re: 2004 Chevrolet Express 2500
Post by: Flyin6 on November 03, 2021, 08:53:02 PM
Don may have a 6.0 for it soon… ;)
I just may!

Dave, rebuilding yourself makes total sense. What do you really get buying new? Nothing really.

I'd consider buying one of Chevy's plug and play 6.2 liter setups with a 6-speed. Remove and reinstall, and with a warranty from Chevrolet. A lot more power, way better fuel economy, proven GM setup, and your van will feel much stronger with that low 1st and 2nd gears.
Title: Re: 2004 Chevrolet Express 2500
Post by: dave945 on July 12, 2022, 07:23:37 AM
So the engine has been having a major miss, check engine light and hesitation for a while now. I finally got the time to take the engine cover off and swap plugs and wires for an initial attempt to clean up how it was running. As soon as I took the engine cover off, I found this.
(https://uploads.tapatalk-cdn.com/20220712/683a691353e2b270414f2ec19dae71d2.jpg)

After reconnecting the plug wire to the coil it ran a little better. Still swapping all the plugs and wires. I’ll let your know how it is after.


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Title: Re: 2004 Chevrolet Express 2500
Post by: TexasRedNeck on July 12, 2022, 07:55:15 AM
(https://uploads.tapatalk-cdn.com/20220712/64f6a8bfe7befbcb3be5a03b738007f7.jpg)


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Title: Re: 2004 Chevrolet Express 2500
Post by: Bigdave_185 on July 12, 2022, 08:40:25 PM
(https://media1.giphy.com/media/VU45vX6kokplC/giphy.gif)


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Title: Re: 2004 Chevrolet Express 2500
Post by: Flyin6 on July 12, 2022, 08:42:27 PM
Dave...Local Dave, that is...You're gonna take some hits!

If you need another 6.0, I have a contact that has two of them on hand
Title: Re: 2004 Chevrolet Express 2500
Post by: dave945 on July 12, 2022, 08:55:27 PM
I know I will, if I didn’t think I could handle it I wouldn’t have said anything. Plus, that’s part of what I like about this community. No pulling of punches.


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Title: Re: 2004 Chevrolet Express 2500
Post by: EL TATE on July 13, 2022, 05:22:31 PM
don't feel bad, paid $170 in diagnostics and $200 in flat bed towing to find out I had left the fuel rail harness unplugged in my 1991 Beretta pace car. (bitchin ride btw) and this is 1999 money we're talking about. at least you solved your own mystery.
Title: 2004 Chevrolet Express 2500
Post by: dave945 on July 13, 2022, 05:32:51 PM
Swapped out all the plugs and plug wires. All the old wires were breaking and coming apart when I was removing them. I’ll post a pic of the plugs for everyone’s enjoyment. Also found two  broken exhaust manifold bolts on the rear passenger side, and one broken on driver side rear.  I’m going to try the Dorman clamps for the exhaust manifold and see how they work out.


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(https://uploads.tapatalk-cdn.com/20220713/a0c8303bd8cf43b5e1cbdc44df18bb4f.jpg)
Title: Re: 2004 Chevrolet Express 2500
Post by: KensAuto on July 14, 2022, 01:54:20 AM
When you installed the wires did you make sure to connect both ends?

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Title: Re: 2004 Chevrolet Express 2500
Post by: Sammconn on July 14, 2022, 08:52:28 AM
When you installed the wires did you make sure to connect both ends?

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😂
Title: Re: 2004 Chevrolet Express 2500
Post by: dave945 on July 14, 2022, 09:52:58 AM
I only connected four of the plug wires directly, i spliced the others into a switch panel so I can have a  Variable Cylinder Management system to save gas. Plus that will make the engine last longer since I’m only use a portion of it.
Title: Re: 2004 Chevrolet Express 2500
Post by: wilsonphil on July 14, 2022, 12:15:39 PM
don't feel bad, paid $170 in diagnostics and $200 in flat bed towing to find out I had left the fuel rail harness unplugged in my 1991 Beretta pace car. (bitchin ride btw) and this is 1999 money we're talking about. at least you solved your own mystery.

Dont know which part of this post is the worst part, spending the money on a screwup OR admitting to owning a Beretta Pace Car?  it hurts just thinks about it
Title: Re: 2004 Chevrolet Express 2500
Post by: stlaser on July 14, 2022, 12:39:29 PM
Hard to believe they allowed there to be a beretta pace car in the first place…… but yes Tate admitting he owned one too! Lol
Title: Re: 2004 Chevrolet Express 2500
Post by: dave945 on July 14, 2022, 12:42:56 PM
Would you prefer he admit to owning a ford Probe?


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Title: Re: 2004 Chevrolet Express 2500
Post by: stlaser on July 14, 2022, 02:06:34 PM
Would you prefer he admit to owning a ford Probe?


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Honestly, they’re in the same category however I think the probes were actually somewhat fast if I recall…..
Title: Re: 2004 Chevrolet Express 2500
Post by: EL TATE on July 14, 2022, 02:29:08 PM
don't feel bad, paid $170 in diagnostics and $200 in flat bed towing to find out I had left the fuel rail harness unplugged in my 1991 Beretta pace car. (bitchin ride btw) and this is 1999 money we're talking about. at least you solved your own mystery.

Dont know which part of this post is the worst part, spending the money on a screwup OR admitting to owning a Beretta Pace Car?  it hurts just thinks about it

um, excuse me, who WOULDN'T want to own this magnificent beast in a 3.1L monster powerplant and automatic trans combo?
Title: Re: 2004 Chevrolet Express 2500
Post by: dave945 on July 14, 2022, 03:35:10 PM
Them’s purty colors. 


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Title: Re: 2004 Chevrolet Express 2500
Post by: wilsonphil on July 14, 2022, 03:52:22 PM
AHHHHHHHHHH now my eyes hurt!
Title: Re: 2004 Chevrolet Express 2500
Post by: Sammconn on July 14, 2022, 06:31:59 PM
AHHHHHHHHHH now my eyes hurt!
X2

 :beercheers:
Title: Re: 2004 Chevrolet Express 2500
Post by: stlaser on July 14, 2022, 06:39:23 PM
Well, if that doesn’t take you back to the 90’s I’m not sure what does…..

I believe the 90’s was the last time I owned a running gm vehicle too!
Title: Re: 2004 Chevrolet Express 2500
Post by: Bigdave_185 on July 14, 2022, 09:17:12 PM
I had a auto shop teacher that collected the geo metros.  Had a whole shop full of them!!
We did tons of learning on them.  At one point we stuffed a gas powered leaf blower into the engine compartment attached to the air intake hose. String for throttle on and off. Did pretty well for what it was for a power increase. Terribly noisy going down the street lol


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Title: Re: 2004 Chevrolet Express 2500
Post by: KensAuto on July 14, 2022, 09:20:02 PM
Them’s purty colors. 


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Looks like something someone from Washington would own...
.. at least it's not a Yugo, Renault Alliance, or an any car from the 80s.

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Title: Re: 2004 Chevrolet Express 2500
Post by: dave945 on July 16, 2022, 11:51:23 AM
It’s all buttoned back up for now. All plugs and wires replaced and connected. I received the exhaust manifold brackets from Amazon and installed them. They were well packaged and quite stout.   Seemed to be about 5/16 thick brackets(I didn’t measure” and cam with the necessary bolts for install. Installation was easy and straightforward except that I couldn’t fit my torque wrench into the spot it needed to be so I free handed it.   Took it for a test drive and it definitely drives/accelerates better and there is quite a bit less noise, and no noticeable exhaust leaks from the manifold.

Still has a check engine light, but need to get to the auto Parts store to use their scanner and see what’s complaining now.
Title: Re: 2004 Chevrolet Express 2500
Post by: Bob Smith on July 16, 2022, 01:12:44 PM
Those existing codes might need to be cleared with the scanner and all might be well
Title: Re: 2004 Chevrolet Express 2500
Post by: Flyin6 on July 16, 2022, 05:19:24 PM
Those existing codes might need to be cleared with the scanner and all might be well
X2. Clear the codes and I bet you're going to be "ops normal"
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