2003 Chevrolet Kodiak / GMC TopKick C4500 and C5500 Break New Ground in Medium Duty Trucks
FOR RELEASE: March 6, 20022003 Chevrolet Kodiak / GMC TopKick C4500 and C5500 Break New Ground in Medium Duty Trucks
So many market-driven design innovations have been engineered into GM’s new conventional-cab line of Class 4-5 trucks that it’s safe to say the medium-duty segment will never be the same again. In fact, the launch of the new 2003 Chevrolet Kodiak / GMC TopKick C4500/C5500 Series trucks has set lofty new standards for best-in-class vehicle capability, durability and performance.
These new models are the most-researched and technically advanced line of commercial vehicles ever developed by General Motors. In addition to their unparalleled maneuverability and visibility, these new trucks sport improved powertrains; stronger, more-versatile frames; a fresh, aerodynamic exterior design and safer, more comfortable interiors. Plus, there’s a wide range of vehicle configurations to suit nearly every medium-duty application. The C4500 Series carries a Gross Vehicle Weight Rating (GVWR) of 16,000 pounds, and the C5500 is available in 18,000- and 19,500-lb GVWRs.
“Our new medium duty lineup showcases GM’s continued focus on the commercial side of the business with durable, long-lasting, professional-grade products that offer high levels of productivity and efficiency,” said David Dunahay, brand manager of medium duty products, GM Fleet and Commercial Operations. “Operators will love the ride, handling, superior visibility and outstanding maneuverability – along with all the comfort and safety features we’ve designed into this family of trucks.”
Capable
Increased maneuverability can mean increased safety and time-savings – things that commercial truck customers really care about. So, thanks to new steering geometry, longer front suspension springs and a set-back front axle, maneuverability in the new models is best in class.
The wider front tracks of the Kodiak / TopKick C4500/C5500 Series models permits a 53-degree wheel cut and greater stability, allowing turning diameters as low as 35.3 feet. On average, that equates to curb-to-curb turns from 17 to 19 feet shorter than in comparable competitive products. The complete redesign of the steering system and axles provides excellent on-center feel, effortless tracking on the highway and minimal correction on rough roads. Entry and exit into the cab is also easier, thanks to well-placed and generously sized steps and convenient assist handles.
Already boasting the least amount of unscheduled downtime in their class, according to J.D. Power, these new medium duty trucks have been designed to provide even more reliability and durability, and are also easier to service should repairs become necessary. A unique service design, called “Priority Access System”, integrates components into major modules within the engine compartment allowing groups of parts to be removed by a technician either independently or in sequence, depending on how much accessibility is required.
Other upgrades have been engineered to increase reliability and lower the overall cost of ownership. For instance, all C4500 / C5500 Series models are designed off a medium-duty chassis that features a more robust and durable foundation frame, constructed with higher 50,000- and 80,000-psi strength steel. Braking system design improvements include not only longer design life, but also simpler disc brake pad removal-and-replacement process and color-coded air-brake manifolds for error-proof line repairs make for faster service during required maintenance. The electrical system has been redesigned to take advantage of new multiplexing technology, meaning fewer wires and connections doing more work with less complexity. And a whole host of new service design features have been engineered into all new Duramax engines, resulting in higher durability with lower operating costs.
Other key components, such as new bolt-on door hinges validated to a half-million full-load duty cycles and improved regulators, handles and check links, have been upgraded for increased reliability. A new, one-piece engine accessory-mounting bracket allows for better alignment of all the components for longer drive-belt life. The trucks’ air conditioning systems feature self-sealing lines, which can be disconnected without the loss of any refrigerant, while new “snap to connect” power steering and air brake lines can help make repairs that were once tricky now fast and easy.
Even the exterior paint features a long-lasting, fade-resistant, high-gloss finish to keep the truck looking newer, longer. These and a myriad of other serviceability enhancements in a variety of critical areas combine to significantly improve customers’ bottom-line profits.
Commanding
Another major factor contributing to safety and cost-savings is increased visibility. Visibility in the new models is best in class, thanks to an aerodynamic sloping hood design, a windshield that is some 40-percent larger in area, and integral convex outside rearview mirrors which are larger than the old door/cab-mounted mirrors. The state of the art exterior mirrors, attached to the body-side cowl to greatly reduce vibration during operation, can fold forward and backward making them less prone to damage.
The net result is the ability to see objects on the ground as close as 13.8 feet in front of the truck (as measured from the front bumper), which gives a 13-foot sight advantage over comparable competitive models (with their average of 26.8 feet). That’s even better than the forward visibility measurements of many compact pickup trucks!
In medium-duty trucks, power and torque is the name of the game. To that end, available Duramax 6600 turbodiesel and Vortec 8100 V8 gasoline engines drive the Kodiak / TopKick C4500 and C5500 Series trucks to the head of their class in both power output and performance.
The Duramax 6600 with 300 horsepower at 3100 rpm and 520 lb-ft of torque at 1800 rpm, outmuscles competitors such as the Ford PowerStroke 7.3-liter V8 and Cummins 5.9-liter six-cylinder diesels. The standard Vortec 8100 also provides a higher, new best-in-class gas V8 rating of 325 horses at 4000 rpm and 450 lb-ft of torque at 2800 rpm. Lower-rated Duramax and Vortec versions are available to optimize fuel economy.
Both the Duramax 6600 and Vortec 8100 mate to high-capacity transmissions, including a electronically controlled Allison 1000 five-speed automatic or a fully synchronized ZF six-speed. The Allison offers a Power Take Off (PTO) option – available for the first time in a conventional-cab GM Class 4-5 truck.
To go along with all that class-leading power is world-class braking, thanks to new hydraulic four-wheel antilock disc-brake systems with standard four-channel ABS, Electronic Brake Distribution (EBD), and available traction control. The C4500 and C5500 trucks use two systems to optimize performance for particular GVW requirements, but both offer reduced stopping distances, lower pedal effort and quieter, longer-life operation.
Depending on the required capacity, the brakes use either a HydroBoost (C4500) or HydroMax (C5500) booster for their actuation. Both operate on the same principle, with the power steering pump supplying the booster power. A tandem (split) master cylinder provides the independent front and rear circuits for the hydraulic brake system. Sensors warn the driver of “low fluid” or secondary brake failure. A traction control system, available for the first time, helps in improving acceleration and vehicle stability on slippery surfaces by employing the ABS hardware to help control wheelspin.
Complete
The totally redesigned and re-engineered Kodiak / TopKick C4500 and C5500 Series trucks enjoy an expanded model range for complete freedom of choice, allowing customers to find exactly the right truck for the job. Available in regular, commercial and RV cutaway chassis cabs in two-wheel-drive, there are also six special vocational packages offered, including School Bus, Shuttle Bus, Ambulance, Fire and Rescue, Wrecker and Snowplow applications. Crew cab and four-wheel-drive models will be phased in later.
The key to low-cost modifications rests with new superior-strength frames. All models share a stamped, straight-section, C-channel frame, providing maximum strength and a clean back-of-cab design for easy, low-cost body and equipment installations. By using three variations of frame strength, GM’s Class 4-5 models optimize weight- and load-carrying capability for their specific applications, without requiring any reinforcement.
The C4500 and C5500 frames are so strong that even the lowest-rated frame has a higher strength rating than the 36,000-psi rating of the steel used in comparable competitive frames. New crossmembers are web-mounted to the frame, providing additional torsional stiffness and rigidity. The stronger, longer frames allow wheelbases ranging up to 235 inches, with plenty of rear overhang for upfitter applications. Fuel tanks, available in four different capacities, are mounted cleanly between the frame rails. They include 40- gallon, 60-gallon and 80-gallon single tanks, and 40-gallon capacity provided by dual tanks.
Comfort
Finally, the new Kodiak / TopKick C4500 and C5500 Series models improve on the best-in-class ride and handling features of the previous-generation C-Series. Tuned tapered-leaf and multi-leaf spring suspensions combine with a new three-point cab mounting system to optimize the flexing capability designed into the new, stronger frames. These new trucks are substantially quieter – achieving a 50-percent reduction in NVH (noise, vibration and harshness).
New cab designs provide more room and comfort by blending the operator-friendly feel and easy-to-use controls of light-duty trucks with the functionality of a true medium duty. A full range of seating options is available for one to six passengers (three to six with the crew cab model), including driver and front-passenger air suspension seats for optimum comfort. There’s even more front-seat head, shoulder and hip room. To enhance safety in the event of a collision, a driver-side airbag is available along with an available passenger-side airbag with on/off switch.
Powerful climate control systems are capable of heating and cooling cabs twice their size, and gas-engine models also provide best-in-class defroster performance. Amenities include a range of high-quality Delco audio systems, large cupholders, map pockets, 12-volt power points and flexible storage, including seat-delete options for extra interior room and a step-well storage compartment, complete with a locking hinged door.
Whether the choice is the dependable, durable Chevrolet Kodiak or the innovative “Professional Grade” GMC TopKick, consumer-focused GM engineering ensures that the new C4500/C500 Series medium duty is indeed the right truck for the job.
Building a Better Truck
Thanks to major renovations and expansion, General Motors’ Flint (Michigan) Assembly Plant has become GM’s new core commercial truck manufacturing center. New, state-of-the-art equipment and machinery and the best practices and processes of GM’s light-duty truck plants are being used to produce the 2003 Kodiak / TopKick line with improved quality and more efficient customer delivery. For example, some 80 percent of the operations in Flint’s new body shop are now automated, with robotics providing consistent high-quality welds and sealant applications from one build to the next.
What’s more, the new trucks also have a high degree of parts commonality, which simplifies assembly and further enhances quality. Many former regular production options (RPO) and special equipment options (SEO) are standard.
GM’s Janesville, Wisconsin, plant will continue building current-generation medium-duty trucks and the current 3500 HD products into mid calendar year 2002, to ensure product availability for customers during the transition to the new products at Flint.
Building Sales, Service and Marketing Partnerships
A new joint venture, General Motors Isuzu Commercial Truck, LLC (GMICT) now consolidates General Motors and Isuzu medium duty commercial vehicle sales, service, and marketing functions in the United States. The partnership, announced in 2000, is designed to better meet dealer and customer needs and long-term growth in the medium-duty commercial vehicle segment.
GMICT takes advantage of the established strengths of both organizations by improving operational efficiencies for the GMC, Chevrolet and Isuzu dealer networks. The GMC, Chevrolet and Isuzu brands remain intact while advertising and sales promotion are developed and implemented jointly. With the combined GMC, Chevrolet and Isuzu medium-duty truck dealers, the new company serves over 750 dealerships.
# # #
All product information is based on the latest information at time of production and is subject to change without notice.
For the most detailed and up-to-date product information, please visit the www.gmfleet.com
