I asked for trouble and I got it.

[solismaris]

So I asked for trouble and I got it. I asked my mechanic to do a comprehensive safety and breakdown check on my 2004 GMC 2500HD. Because breakdowns on vacation are no fun - we've had 2 already this year - and stressful for me and the wife, and I wanted to find problems before they happen. Bad idea? Maybe; maybe not.

Not suprisingly he found lots of problems. Brake issues front and rear, badly rusted control arms, etc. Most of them I understand and accept and will have them done over the next few months, one at a time. But the big one is this:

He says the fuel lines are badly rusted and strongly recommends replacing them, and that job includes new fuel pump and tank straps. It is an 8 hour job and estimated at $1800 parts and labor!

First of all, that's a shockingly large amount of money! Does this seem out of line? He says the entire system is one part, basically, from fuel tank to engine, and is $1000 just for the part!

Second: Is it appropriate to change this just because it is badly rusted? Would there be warning signs before impending failure (like a slight odor of gasoline)? Or would my only warning be the giant fireball as the line ruptures and sprays gas all over the exhaust and sets us on fire? What would you do? (All opinions welcome!)

[dodge_guy]

Sounds about right! I would recommend replacing all the brake lines along with he fuel lines. Go all stainless so you never have to worry about it again!

With that said, what else is so rusty on it that may fail? Maybe the rear spring shackles? Some frames can rust through. Might be time to start looking into a newer truck!

[bucky]

Stainless brake and fuel lines are readily available in the aftermarket.

[solismaris]

Amazingly, the truck looks decent from a body standpoint, no rust in sight. All systems run great. Chrome on bumper peeling that's all.
Brake lines on the front replaced 2 years ago, back lines very ugly but not at the point yet of rupture. Scheduled to be done next week.

[time2roll]

Too bad there is no stainless steel option. I mean many exhaust systems are stainless why not fuel and brake lines? Seems a bit more critical.

[ExxWhy]

Fuel lines being severely rusted does not surprise me at all. Many people who do not live in the rust belt have a difficult time wrapping their brains around how bad the rust problem really can be. Replacing the fuel pump is wise, it would be one of the most likely non catastrophic things that could leave you stranded on an older GM, very common failure. Price seems a bit high, but maybe dealer parts as mentioned. I would also wonder about brake lines, they are usually just as bad.

That does lead me to also wonder if this truck is worth it. Cab corners might be 1 more winter away from looking like swiss cheese. Door bottoms, wheel wells, how does all that stuff look? Might be better off taking a little road trip to one of the non rust states and buying a similar vintage truck for the same money as you will have invested in the rusty one.

[Bird_Freak]

My buddy lives in Maryland and has a 04 like yours. His brake and fuel lines rusted out several years ago. Replace them.

[LanceRKeys]

Do it. Call around for prices, but do it. I just drove home with my family in a rental car because my rear axle bearing failed while the trailer was on and ruined the axle housing $$$. Now I will have to drive back when they finish the truck get the trailer and drag it home. In my case an ounce of prevention would have been worth a bunch of pounds of cure.

[bucky]

Yes, there will be a warning. It's called a fire.
If you haven't had the brake lines replaced yet I'm wondering if the shop doesn't know the difference between fuel and brake lines. The fuel pump sending units were known to rust at the top of the tank, but I've never seen fuel lines in that model rusting before brake lines.
Your own eyes or a buddy are your best next move.

[Ductape]

If reliability far from home is your goal, an older truck with an increasing number of replacement parts is likely not going to deliver that. Few mechanics are capable or caring enough to install to factory standards. And aftermarket parts? A total crapshoot.

I maintain some older vehicles myself. But with my own labor and OEM parts.

Rust never sleeps. If it's to the point of control arms and lines, better get a second opinion. Pretty soon you'll be into sunk costs and telling yourself you can't quit now.

[Walaby]

Me Again wrote:
I think you should check with a GM dealer as some fuel line issues are covered by an extended warranty that GM put in place as the result of the danger of a failure. Chris

Extended for 15 years for a rust problem? Seems like a huge stretch to me.

OP - if the repairs are out of your skill set, then you really have only two choices. Research youTube and give it a shot yourself, or pay the piper.

That is a lot of repairs for a 15+ year old truck. Im with those who say show me the rusted fuel line. It may very well be, but I'd have to see it first hand before I paid someone to do that.

Mike

[rexlion]

The shop may be quoting price for an OEM part. If you prefer a cheaper part from an auto parts store, ask the shop if they will do that to save you some money. Often they have more than one source, and flexibility.

[Me_Again]

I think you should check with a GM dealer as some fuel line issues are covered by an extended warranty that GM put in place as the result of the danger of a failure. Chris

[dugwms]

Actually, the job isn't as bad as you might think. I replaced fuel and brake lines on ours and I had no experience doing that kind of thing. Take your time and study up beforehand. Brake lines were harder than fuel lines. Fuel pump isnt hard. Ours was an 02.

[danrclem]

Are any of these what you need?

https://www.rockauto.com/en/catalog/gmc,2004,sierra+2500,6.0l+v8,1425226,fuel+&+air

[Grit_dog]

mtofell1 wrote:
I ultimately got rid of my 06 Chevy 2500 because of all the nickel and dime repairs. The Duramax diesel engine and allison tranny were great but it seems like every other oil change there was $1000+ in repairs to suspension parts, hubs and junk like that. At 15+ years old I'd have a hard time putting that much money into a vehicle. Once you fix one set of problems something else is going to start having problems. I bought a new truck in 2014 and haven't spent a dime on anything other than routine maintenance.

Different scenario being from Oregon than the OP's. Nickels are nickels, but he's dealing with the parts wearing out AND rust destroying parts that would last 40 years here. (Unless you live in the mountains)