Best 3rd Gen Year, Truck Stolen Time To Replace

[therobzilla]

Hello,



Let me start by saying, I have up to this point been a 2nd gen guy, and finally had my truck setup the way I wanted it. I was very happy going for the 500K miles. It was stolen right out of my driveway about 6 weeks ago, and I am finally settling with the insurance company.



It's time to replace, but after getting beat up by the insurance company, I think I'm going to upgrade to the 3rd generation.



My second gen had everything, exhaust, clutch, 5 gear quad 4x4 mainshaft, everything, injectors,... ... . more than I care to type all out.



I have historically run Manual trans, but am thinking auto now.



Let me tell you what I tow and how I used my old truck, and maybe you could give some opinion on the 3rd generation trucks. As I have no clue about the pitfalls/issues with the years.



I tow a lance full size 1121 slide in camper heavy, I also when the camper is loaded, tow my rockcrawler behind it, I tow with the Torklift/Superlift hitch. And had Exhaust brake and Brakemaster controller on the 2nd generation. My second gen had 275 injectors and and Edge ez and was perfect for towing. The other thing is I live in Arizona, and summertime towing is not out of the questions, and interior AC is important. Must be 4x4 and must be a quad cab, and must be a dually.



So here are my questions in no specific order:



Was there a specific year to avoid

Which years were better?

Have the Auto Transmissions gotten any better since the 2nd gens?

Which years are the better years for the Autos?

What do I have to be worried about on the 3rd gen years?



I know It's a bunch of questions, but I have enough to upgrade to a 3rd gen and I just don't know enough about them, and help or links would be appreciated.



I'm excited about the 3rd gen, but nervous as hell about which ones I should be looking at.



Thank you very much in advance.



Rob

 

[rbattelle]

Well, you'll get a ton of different opinions, of course. I guess since I'm up late I get to offer mine first!

I think the best years for 3rd gen trucks are 2003-2004. 5. These are the last vehicles offered for sale in America with NO emissions equipment. They probably get the best mileage of any 3rd gen trucks. And they still use the traditional electrical system (as opposed to the more advanced and harder-to-work-with Totally Integrated Power Module).

I don't think there's any specific year to avoid - there really aren't many complaints about any of the 3rd generation. Automatic transmissions are better, as long as you're looking at the 48re (which wasn't released until 2004, I believe).

Things to worry about on 3rd gen trucks are:
1. Injectors are sensitive to contaminants and can malfunction resulting in major engine carnage (if they stick open).
2. 2003-2004 trucks frequently have vibration complaints between 60 and 70 mph.
3. The fan clutch wiring harness on the 2003-2004 trucks can sometimes rub the radiator, eventually rubbing a hole right through.
4. Lift pumps! The factory lift pump located on the fuel filter canister is notoriously unreliable. A replacement in-tank pump is now available, and most trucks that have had an LP failure under warranty will have been retrofitted.

There are some other issues, but I can't remember them right now. Here's a couple threads to look at for common problems:
Thread 1.
Thread 2.

Ryan

 

[Motorhead]

I went from a 2001. 5 second gen to the '07, 5. 9. I learned from the site which truck to look for. I was able to find mine that was built in Dec. 2006. It got the later, 6. 7 ratio G56 but still the 5. 9. This truck is way nicer than my '01. 5 in my opinion. I personally didn't like the auto for towing only because there was too much gap between 3rd lock-up and 4th lock-up. My LATE G56 has about 500-600rpm between gears. I spent $3200 on my '01. 5 trans with a complete DTT set-up. All I got to do is put a Southbend DD3250 clutch in my '07 and I am set.
My '07 doesn't have any rattles like my '01 had. Bigger seating in back, MUCH quieter engine. With a Smarty jr, I am getting close to the same MPG with more HP.

 

[RHestand]

IMO my 98 dually is much more comfortable on long trips, compared to my 06 2500.

We just returned from a 3000 mi. trip, and my wife and I both were pleasantly surprised.

I think it might be the seats.

Speaking of seats, the cloth on my 06 seats was worthless.

Given a choice I'd take, leather and a G-56, on a 3rd gen.

Ray

 

[ekroman]

Rob:



Sorry to hear of your loss. It sucks when someone takes off with your pride and joy, especially after all that work to get it where you want it.



I just bought a 2008 two weeks ago, with the 6. 7. Now, I know a lot of guys don't like the 6. 7 because it's much easier to modify the 5. 9. I seem to remember this was a gripe with the 24v engines when they first came out: everyone prefered the 12v, because we knew what to do with them.



I really like the new 6 speed auto with the 6. 7's. It works much better than my previous trucks; the 95 and the 90 are both autos. After swearing I wouldn't buy another auto, my wife encouraged me to try one (she thought it best if we get an auto. )



If you're jumping to a third generation, and you want to modify it, I suggest sticking with the 5. 9 for now. Unless, of course, you're going to start bombing it a year or two from now. The aftermarket will have caught up more with the 6. 7.



I love the interior on the '08. Very nice. The '95 wasn't bad. The '90 was primitive, but hey, it's a First Gen, and they're very truckish.



Eddie

 

[Bill Stockard]

I haul a Lance 1121 camper with my '03 3500 DRW, but don't tow anything. I've hauled large heavy Lance campers on my previous second generation trucks. The suspension on the third generation is "softer" than the second gen. You will need to add an anti-sway bar since they aren't available from the factory and consider adding other equipment. (See my signature) When the Lance 1121 is loaded for traveling, our 2-wheel drive truck is 500 lbs over (on the scales) the GVWR.



Yes, the 48RE automatic transmission is improved over the earlier automatic transmissions. IMO, the torque converter is still a bit too loose. I like that way torque converter not only locks up in third gear and overdrive (4th gear), but will lock up in second gear when manually shifted into second. The later model third gen 48RE transmission works well with an exhaust brake.



Since I don’t tow, the engine power (305 HP) is very satisfactory for me. I haul my Lance camper on my truck 95% of the time (not a daily driver) and it averages 14 MPG. All my fuel purchases are recorded and averaged using a MS Excel spreadsheet since I bought the truck new in ’03.



I also like the quieter engine and it’s one of the reasons I replaced my ’00 3500 dually. The cab is much better and no “suicide” rear doors. I have found that the camper must be centered in the truck bed or the rear doors will interfere with the dually camper jacks when they are turned in. If the camper is loaded too far off to one side, you’ll have to swing out the jack on the opposite side to clear the door; however, it's not a problem if the camper is centered.



I used Torklift camper tie downs on my second gen trucks, but the front driver tie down interfered with the fuel door on my third gen truck. However, Torklift may have made changes since ’03.



Overall, hauling my ’03 Lance 1121 on my ’03 3500 DRW Q-cab, I couldn’t be more satisfied. It’s a real improvement over the ’00 3500 DRW 6-speed Q-cab I previously owned… and I don’t miss the 6-speed.



Bill

 

[jgillott]

I'm going to contradict myself in this post, so I will apologize from the beginning. Anyway, after 3 in a row now... a '92, an '01, and now this '07, I like the '07 the least and I have no Idea why. It's softer riding, quieter, more comfortable, and easier to drive daily than anything I've owned. But I don't like it. It tows better, stops better, handles better in the snow, and goes amazingly well off-road for a stock suspension truck. But I truly don't like it anywhere near as much as my previous trucks. My wife always said that I'm difficult to please... . guess she's right :-laf



As far as reliability of the trucks and the 48re in particular is concerned, from what I've seen, they are very good, especially in stock form. My brother-in-law has a very early build '04. 5 with the 48re auto that he purchased new. It is bone stock except for a 4" cat back exhaust and an AFE drop in filter. That truck is the most abused and neglected truck I have ever seen, and to date it has been 100% reliable. It has a little over 150,000 miles on it now and I think he has changed the oil maybe 3 times total . Other than that, he hasn't done any other maintenance. No trans services, no fuel filters, etc. He drives it around 120 miles a day, it is working off road with heavy loads 2-3 times a week, is covered in mud inside and out, never washed, and it just keeps going.



Anyway, I don't think that you could go wrong with any of the 3rd gen trucks. As others have mentioned, each version has a few little issues that make them better or worse than the others. I would just try and find one in the configuration you want in the best condition possible and go from there.

 

[CumminsBu]

Well, you'll get a ton of different opinions, of course. I guess since I'm up late I get to offer mine first!



I think the best years for 3rd gen trucks are 2003-2004. 5. These are the last vehicles offered for sale in America with NO emissions equipment. They probably get the best mileage of any 3rd gen trucks. And they still use the traditional electrical system (as opposed to the more advanced and harder-to-work-with Totally Integrated Power Module).



I don't think there's any specific year to avoid - there really aren't many complaints about any of the 3rd generation. Automatic transmissions are better, as long as you're looking at the 48re (which wasn't released until 2004, I believe).



Things to worry about on 3rd gen trucks are:

1. Injectors are sensitive to contaminants and can malfunction resulting in major engine carnage (if they stick open).

2. 2003-2004 trucks frequently have vibration complaints between 60 and 70 mph.

3. The fan clutch wiring harness on the 2003-2004 trucks can sometimes rub the radiator, eventually rubbing a hole right through.

4. Lift pumps! The factory lift pump located on the fuel filter canister is notoriously unreliable. A replacement in-tank pump is now available, and most trucks that have had an LP failure under warranty will have been retrofitted.



There are some other issues, but I can't remember them right now. Here's a couple threads to look at for common problems:

Thread 1.

Thread 2.



Ryan

Second what Ryan said.



03 had the most engine transmission combos:

5. 9 HO to NV5600 (305hp 555tq)

5. 9 HO to 48re

5. 9 SO to NV4500 (250hp 460tq)

5. 9 SO to 48re (rare I believe)

5. 9 SO to 47re

5. 9 CA SO to 47re (all Cali engine 235hp 4??tq)



04:

5. 9 HO to NV5600

5. 9 HO to 48re



4. 5:

5. 9 HO to NV5600 (325hp 600tq)

5. 9 HO to 48re



05:

5. 9 HO to NV5600 mid year change to the G56 with only 3. 73:1 rear end gears.

5. 9 HO to 48re



06:

5. 9 HO to G56

5. 9 HO to 48re



07:

5. 9 HO to G56 at some point they changed the gear ratio and 4. 10:1 is an option

5. 9 HO to 48re



07. 5:

6. 7 HO to G56

6. 7 HO to 68re



08:

6. 7 HO to G56

6. 7 HO to 68re



I would also add in 06 and up they changed the dash. So I prefer the 03 to 05 dash better.



In 07. 5 they went with large track-bar bolt on the front and a one piece drive shaft for the long-bed and mega cab.

 

[CDonaldson]

Rob.



Sorry to hear about your loss, it is getting down right rediculous out there regarding theft, almost need to stand guard over your truck these days. I have the factory alarm and the Ravelco. They will need a flatbed to steal mine.



I have to say that I have nothing but GOOD to say about my 2006. It IS truly an excellent all-around truck, gets decent mileage, easy to maintain. I tow, and tow heavy all the time. Probably the only thing that I felt needed a little mouth-to-mouth was the suspension. The soft ride systems in our trucks today have somethings to be desired if you are looking for that caddy like boat floating, but when you get into heavy loads or heavy tows the DO need some changes. You will see by my sig what I did, it is all working out well for me.



I am pretty much a standard transmission person BECAUSE I tow, nothing beats what a standard transmission can do towing. I have a couple friends with the 5. 9's and the later version of the G56, the gearing change is a little better on fuel mileage over my earlier G56, but truthfully, not enough to make that big of a difference in the overall performance.



If I were to be in a position to replace the truck I have now, I would look for what I have now first before going to the 6. 7 or going with the auto transmission. If I was looking to change to the 6. 7 and also to an auto transmission, then I would just get a new truck with the 6-speed auto. Almost all the guys who tow heavy end up beefing up their auto trannys, the new 6-speed auto seems to be performing much better than the older ones and not many have talked about billet mods, etc as of yet.



Good luck with your search for a new truck, beyond that I am sure your choice will be a satisfying one regardless of what you get in finality.



CD

 

[Blu-meanie]

I certainly had much more trouble with my '01. What I miss about it is the bright blue color, the seats, the diesel smell, and the 410 gears. It was at the dealer for about a month total while they tried to figure things out.

My '05 has only been in for a steering box and a leaky carrier seal. I don't like the seats, but I do like towing with it better. For the first year, I kept trying to get into the back seat to drive :-laf

 

[Regcabguy]

With your goals, if you go with the 5. 9 in any third gen. ,it's going to need a clutch(G-56) or major auto upgrade. My suspension was so woefully inadequate when I installed my 2000# Northstar,my Lorenz suspension was mandatory. Airbags aren't going to cut it. Longer,stiffer front coils,larger revalved shocks and preferably Carli long travel airbags. If that big of a Lance is going on there all the time get a dually. With the dually,less suspension upgrades will be needed. I had a '99 and much prefer this '07 5. 9. I test drove an '06 auto and knew I was looking at a $4500 DTT or Goerend upgrade. With the G-56,I'm loking at an SBC or Valair aftermarket at a fraction of the price. The cats are nothing to worry about,but the '05's simpler power system would be preferable. Good luck.

 

[RVTRKN]

Economy starting to get to me, look at my sig and if your interested in the 04. 5 or anyone else for that matter, I will sell it. I own it and after insurance and service bills its starting to drain my savings. it only has 53K miles and all of the required services performed to include the diff services. Make an offer or PM me. It has been a good truck and is completely stock, and all records to prove service.



BTW, I'll throw in the "lil Rocker RBW hitch.

 

[MickeyMiller]

I concur with Ryan's recommendation, '03-'04. 5. By now they will probably have had the lift pump replaced and a quick visual inspection can determine if you have the fan clutch cable wear issue (I believe that this is only on early '03 trucks). The early '03 trucks also had a weak alternator bracket but if it's still on the truck, it couldn't be that weak! Some of these trucks have weather stripping wear/tearing issues, there is updated weather stripping available. I've enjoyed 110K of largely trouble free miles... LOVE this truck!

 

[Forrest Nearing]

03/early 04's get the best mileage, sound a little better IMO, and no cat converter...



the 03-05's are available with black interior and I think the seats are slightly more comfortable though I wouldn't call any of the 3rd gen seats particularly comfortable for a larger man like myself LOL



I prefer the 06+ headlights (took a while for them to grow on me)



I prefer the 06+ dash



I prefer the 06+ Mega Cab!



I've always been a 12v guy... I've had six of them... I'm on my third Common Rail truck THIS YEAR! LOL! I LOVE my 12v... if I could legally put one in a Mega Cab, I'd probably do it in a heartbeat. But... the Common Rail engines are spectacular. The injection system still kinda scares me, but feed it good fuel w/ good filtration and you'll be alright.



the smoke-free power you get out of them is killer

 

[Yo Hoot]

Love my 04. Factory with ZERO emissions. I think the 04. 5 has a CAT and the extra injection for emissions. They can keep that

 

[Forrest Nearing]

yes, 04. 5+ trucks all have a cat... you got the truck I was looking for when I snapped one day at work and decided that I couldn't do another quad cab. I loved my old 555 truck, but the Mega Cab is so much roomier inside and the auto w/ just a smarty spanks the old twin turbo'd 6sp up to about 70mph! LOL

 

[Kry226]

Love my 04. Factory with ZERO emissions. I think the 04. 5 has a CAT and the extra injection for emissions. They can keep that

+1.



I too love my 04 and bought it specifically for its lack of emissions equipment. At 69K, issues encountered so far (all under warranty):



Front wheel speed sensor

Front diff pinion seal (x2)

Front driver's side u-joint

HVAC blend door



I replaced the lift pump at about 50k with a Walbro from GDP. The OE pump was still working perfectly and I can retrofit if I want to. KORE and BFG 315s have been on since 5k and no ball joint or DW issues. The Cummins and 48RE have been perfect.



If I were in your shoes, I'd be looking for an 04 built before Jan 1, 2004.

 

[Regcabguy]

Make sure with an '03-'04. 5 that you don't get a Ca one. It will be the SO version with a cat.

 

[DHeidloff]

Sorry to hear about your other truck. AS you can tell from my profile I have a 2004. 5, 1 ton with a auto and SRW. I tow a 22 ft boat and haul 10'11" Lance Camper when I am loaded I am pushing 18K. I put on the Vision Type 81 wheels and Hankook 14ply tires. When I am loaded I have 8600 lbs on my drives. Like some one stated before about sway bars this truch is softer than the 2nd gen. I needed help to keep the rear from sagging when loaded and reduce the sway. I had air bags on my last truck On this truck I put on the Timbren Springs and they work AWSOME for me and I was told if I did not like them I could return them. The truck is very stable on the road the rear is just sitting on the helper springs and just above level



I have 90k on my truck I have had 2 problems.

1. Lift Pump

2. TSB #21-009-07

 

[RVTRKN]

Make sure with an '03-'04. 5 that you don't get a Ca one. It will be the SO version with a cat.

04. 5 in CA is the 325/600 CTD. It is the one of the first HO allowed in CA, now there was for a very short time (60 days) the 04 HO 305/555 you could get here. Mine is the 04. 5 325/600 purchased in April of 04. I would not buy a CTD until they allowed a HO, which at the time I was not aware of the new 600 CTD and was lucky when purchased.