I've got a 2004 Suburban 1500, 4x4. I've had it for five years, commencing at 130k and now at 240k.

Overall it's been a great truck, but recently I've had some unusual problems and I'm wondering if I should stick to my original plan--which is to just keep fixing it and driving it forever and ever. Current repairs needed include overhauling the rear axle (quote for $600 minimum), replacing the two levers that activate the emergency brake ($300 each = $600 just for the part), and patching and painting the roof. I've got major holes, 2 - 3 inches diameter, around about half of the rack mount sites, and heavy rust on all mounts. That will also be an extensive and costly repair. Ah, and I need to swap out the driver's door panel with the switches for the mirrors, windows and locks. $300 switch panel from Chevy.

In the last two years I've done rear pinion seal TWICE, rear axle seal twice, transfer case housing, U joints, rear gate activator twice, and all of the fan speed resisters. I also got to spend $1,000 diagnosing and fixing a problem with the computers after driving through a foot of water when our neighborhood flooded. For a 4x4 truck that seemed pretty wimpy! That repair took a guy who really knew that system and had those $20,000 scanners to diagnose.

So for anyone in the know, I'm looking for advice on the quality of this generation of Suburban. Are these normal problems? Am I heading into a money pit, or will I reach the end of the big stuff for the next 100 or 150k? I'm even willing to rebuild the motor and transmission when the time comes. I really like the truck and would like to keep it going. I'm just not sure that is the best idea because of all of the unusual repairs.

 

Hmmm - Mrs. Cusser has a 2005 Yukon Denali with AWD and 6.0 Vortec engine, and it's been pretty good (ours since 2010). We're in Arizona, so no rust at all, but she's "scared" of its 228K miles and that its plastic radiator cracked while she was driving in 2018, so we'll be looking at a newer version for her this year. She sometimes tows a horse trailer/horse.

You've been less fortunate in your experiences...

 

Rust = money pit. If you were out west with no rust then no problem you can replace and rebuild forever. Rusted frames and body's are not worth it.
Years of salt zone experience here..

 

I have a 2001 Suburban with 247,000 miles, but mine is 2WD. Of course, I have less potential problems than a 4WD but there is one common denominator that can best be described in the words of my mechanic...it's getting old. The engine leaks oil but seems to burn none; the trans is original and so is the starter if you can believe that! Even my front suspension is still original except for the inner and outer tie rods that I replaced recently. Many other things have been replaced like water pump, cooling fan clutch, power steering pump (twice), ABS unit along the frame, and too many other parts to count. My warranty has been up for years yet almost every replaced part has a lifetime warranty...now that's some funny stuff I don't care who you are! But at some point a decision has to be made as to when is it time to part ways. For me, a rusting body on the truck and my own aging body that prevents me from doing things myself anymore have become the tipping points for me. Should something major like a trans or engine go I would not spend the money to repair or replace them. After 20 years of Chicago area winters my brake lines look threatening as well...definitely not something I can do myself. It is now what I would call a mechanic's special, with an interior that looks showroom new. As for the outside, well, I will say this about that...I recently spotted an old pickup that had more rear fender missing than remaining, and on what was left of a rear bumper was a bumper sticker that said A MAN AND HIS TRUCK...ITS A BEAUTIFUL THING. Truer words were never said, but at what price, that's the question.