Questions about Diesel Maintenance

My Answers in BOLD. I will be using my personal 6.7L Cummins motor as a point of reference. I cannot speak for Duramax or Powerstroke owners. I'm also assuming you are only looking at the current generation of Diesels, nothing used.

otrfun wrote:
My next truck (4x4, CC) has to have a minimum 3000 lbs. of payload. That leaves me with either a 1 ton diesel (3500-4000 lbs.) or a 3/4 - 1 ton gasser (3200-4000 lbs.).

I've run my gasser vs. diesel numbers as far as purchase price, MPG (towing & empty) and resale.

I'm familiar with what's needed to maintain a gasser; however, never owned a diesel. Here's what I know, don't know, about diesel maintenance:

1. Oil costs are approx. double vs. a gasser due to twice the oil capacity.
This depends. If you can use conventional (rarely/never below 0 degrees F), you can use dino 15W-40. You can get 12 quarts (3 gallons) for roughly $40. Only $10 more than what I spent on average for my F-150 running semi-synthetic 5W-20(minimum oil requirement per Ford back then). Or if you go full-synthetic, you're looking at roughly $63 in oil (I buy T-6 Rotella 5W-40 for about $21 per gallon).
2. Oil filter. I assume these cost a bit more than a gas oil filter?
For my truck, oil filters are roughly $11 to $13 for an oil filter. I like the LF16035 since it is a synthetic filter, so I've been spending roughly $13 per oil filter.
3. Fuel Filters. Assuming DIY replacement, what can I expect to pay for filters? How often?
For my truck, it's roughly $110 for both filters. It's a yearly change-out for my truck (annual or 15,000 miles. Whichever comes first)
4. DEF. 2-4 cents of DEF used per a gallon of diesel??
Just to make life easier, I figure a nickel per gallon of diesel. This is assuming you're paying around $2.80 a gallon for DEF
5. Valves. Under normal operating conditions is adjustment ever necessary? If necessary, cost?
Every 150k miles. For the Cummins, you can DIY, just need a feeler gauge and a breaker bar to rotate the engine. Ford and Duramax don't require this service as I believe they both utilize hydraulic lifters.
6. Injectors. Under normal operating conditions is maintenance/replacement necessary? If necessary, cost?
These should last a minimum of around 300,000 miles in the worst of conditions. Longer in better conditions such as higher speed towing

Other diesel specific maintenance items I may have overlooked?
Specific to the Cummins motor, you do have to occasionally change the Crank Case filter which costs about $77 when I last looked. This is done every 67,500 miles. However, this filter does an excellent job of keeping most of the oil mist out of your intake tract. I know Ford utilizes a service-free cyclone crank case filter unit, and I'm unsure what Duramax uses. That's the only thing I can think of adding to your list

Thanks!

Hopefully this helps.