2008 prostar

The majority of those repairs such as batteries, alt, w/p are all routine and should be expected with a used truck. The main issue you are having is going from an EGR only truck to a full aftertreatment truck that is also at the end of its useful life. DPF emission trucks are all pretty much wooped after 7 years. The emission components, wiring and sensor are all simply worn out. They do not last forever. When buying any used truck with DPF emissions you need to see service records of the main aftertreatment components such as DPF, DOC and doser injector have been properly serviced. The DPF may need replacement after time as it won't come perfectly clean after being removed and cleaned. The DOC will simply wear out along with the doser. If you are looking at a used DPF emission truck and nothing has been done then you can expect expensive repairs in the near future.

 

If you're going to go older. I would go with a Pre-EGR motor, 2002 and earlier, you won't have any Emission Issues, but like any used vehicle, you may have other issues that need to be addressed.

 

The older you go the simpler the emissions are, so repairs should be fewer, but the older you go the more worn out the whole truck is, so that is a catch 22. Lots of great used trucks out there. It is just a matter of finding them.

 

Check it regularly. If that friction disc wears down, replace it. A lot of the times, that friction disc goes unchecked, wears down past the tolerance point, and then the fan clutch goes tits up. Staying on top of that will make your fan clutch last longer. Just takes an 8mm socket or ratchet wrench (the latter is a little better for the Cummins, as the space is a bit tighter) to replace the friction disc, and it's a hell of a lot cheaper than letting it go an replacing an entire fan clutch.

Wear item. Are you running an inverter off of them? If you constantly drain and recharge batteries, that's deep cycling, and that'll greatly reduce the lifespan of the battery.

Something you should have to replace once in a blue moon... if this becomes a recurring thing, there's definitely an issue there. Ensure that it's lined up properly, for starters.

Same as with the alternator, provided you don't abuse it.

Same as above re: starter and alternator

That one shouldn't be a recurring thing. If it is, you've likely got a multiplexing short somewhere, and you'll have better luck to replace the entire harness than to try dismantling them and tracing them.

These can be a crap shoot. Normally, they shouldn't have to actually be replaced... a simple cleaning will suffice... but if that "honeycomb" starts forming cracks, it's time for it to go. Same with the DOC... for that year Cummins, I believe you'll have the four piece DPF system... inlet, DOC, DPF, outlet.

Happens sometimes... should not be a recurring thing.

Happens sometimes, especially considering that engine had some miles on it before you got it, I'm sure. Shouldn't be a frequent thing.

Was the one it originally had painted red or was it silver? If it was red, then that was the original doser which came with the engine... yeah, those don't last forever. The new one should last you a good while.

Happens time to time, inexpensive part. Should've been able to replace this yourself and save the labor cost.

Wear items. How long have you had this truck? IIRC, most dealerships ensure the trucks have at least 50% brakes before they sell them. How many miles between buying the truck and changing the brakes? Did they get burned out? The caveat to this is that they'll typically only measure brake depth in determining this, and not actually take off the drums to ensure they're not glazed over.

See the commentary above. The wear out components, definitely. The dosing injector... I've yet to see one where the original didn't have to be changed out within the service life of the vehicle.

Hopefully. The ones which should be rare/occasional things... well, if they're recurring, I'd be a bit worried.

They shouldn't.. the major repairs should last you... unfortunately, I can't guarantee that you didn't get a lemon, nor can I say for sure that you did.

The caveat being that a 2005 or older truck is 10 years old or older... gonna be some substantial wear and tear on those.

I wouldn't recommend spending 25k/year in repairs on any truck. But, a lot of these major repairs should be one-off repairs... time will tell.

Really depends how beaten to #### the truck and drivetrain components are.

Due diligence. Take care of small issues before they get a chance to become big issues. That holds true for any truck.

 

Not familiar with auto shifts. Re: oil pressure, pull codes... I have a feeling you'll see some for "Engine Oil Rifle Pressure Sensor 1 - Data Invalid, Intermittent, or Incorrect" (or something to that effect). Worst case scenario, it's a harness - most likely, it's the sensor itself, and that's a very easy fix... Small screwdriver to slide the harness locking clip out, ratchet and extension, and a 1-1/8" deep well socket.

 

Yeah.... tonight, when I'm off and I can upload a photo.