2004 Chevrolet W3500 Tiltmaster Service and Repair Manual

This factory service and repair manual for the 2004 Chevrolet W3500 Tiltmaster narrows the choice to two: a naturally aspirated 6.0L overhead-valve V8 of 364 cubic inches on gasoline, or a turbocharged 4.8L inline-four diesel of 290 cubic inches. Both sit in the same low-tilt straight truck on the W3S042 specification. The engine chapters carry separate mechanical, fuel and cooling specifications for each, while the transmission, axle, brake, steering and cab wiring sections apply to the truck whichever engine it left the factory with.

Engines covered

• 6.0L V8 (364 cu in) — OHV, naturally aspirated, gasoline
• 4.8L inline-four (290 cu in) — turbocharged, diesel

Body styles covered

• Straight truck, low tilt

Trims covered

• W3S042

Known issues on the 2004 W3500 Tiltmaster. One recall applies to this model year. Solenoids in the diesel fuel switching manifold can admit water or salt and fail, after which fuel is delivered incorrectly and can overflow out of the filler neck, a large leak and a fire hazard if it meets a spark. Complaints are few, four in total: two on engine and engine cooling, one on suspension and one on the fuel system. The fuel, cooling and chassis procedures in this manual cover those same areas.