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Case Study

Vehicle Sector: Courier, Delivery

Industry Sector: Office Supply & Products


Courier and Delivery operation profiles typically include high mileage and occasional heavy loads. This mission profile certainly describes the office supply and products customer. Covering a wide area and routinely hauling many cases of paper put a heavy burden on this Class 1 van.

Near the B50 lifetime for the engine and facing increasing maintenance costs, the owner was interested in the complete remanufacturing service.

Power Train:

At just over 220,000 miles this van was experiencing low power and transmission slipping.


The front and rear shocks and springs were spent. Front end steering and linkages were well worn and sloppy.


Normal wear and tear–but, almost all wear confined to the driver side. This is typical of courier and delivery vehicles as the driver is normally the only occupant.


The exterior condition was typical for the mission profile and age except for one side doo rand one rear door.

Other than the doors, there were several dents and dings. The paint was oxidized with a typical number of scratches and patches. The graphics were beginning to fade, roll, crack and peel.


The extensive remanufacturing service replaced not only the power train, but the major assemblies and subassemblies in the list below.

  • Engine
  • Transmission A/C Kit
  • Radiator, Cap & Hoses
  • Ball Joints (Upper, Lower)
  • Battery
  • Belts, Hoses
  • Brake System
  • Brake, Hydro‐boost
  • Bumper, Paint (front & rear)
  • Detonation Knock Sensor
  • Door panels, Recondition
  • Drive Belt Tensioner Assy
  • Driver‐sideSeatBeltKit
  • Engine & transmission mounts
  • Fender Extension
  • Floormat
  • Fluids and filters
  • Front end
  • Front end alignment
  • Fuel pump
  • Gaskets, engine & transmission
  • Halogen headlamps
  • Headliner
  • Idler Pulley
  • Left rear door
  • Miniature Bulbs
  • Leaf spring, added paint job
  • Passenger side seatbelt buckle
  • Recover driver’s seat
  • Repaired & adjusted both side doors
  • Repaired Rear Exhaust
  • Right front fender
  • Sensor, Camshaft
  • Sensor, Coolant Temp
  • Sensor, Crank
  • Sensor, O2 (all banks)
  • Sensor, Speed (in/out)
  • Sensor, Temperature
  • Serpentine Belt
  • Service & inspect rear differential
  • Shock absorbers
  • Side door entry cover
  • Spark plugs and wires
  • Steering Wheel
  • Thermostat
  • Tie Rod End (Inner, Outer)
  • Tires, 4 each
  • U‐joints
  • Water pump
  • Weather‐stripping
  • Wheel Bearing & Hub
  • Windshield
  • Wiper Blades

Body‐off remanufacturing exposes the frame to allow for easy access to the power train and suspension. The Body is also processed simultaneously to save time.


The replacement powertrain solved flagging power and acceleration issues. Engine and Transmission now work together with a reset lifetime.

The Suspension work restored like‐new ride and feel. Road feel is now coupled to the Steering Wheel through replaced components and steering gear.

Road noise was greatly reduced by replacing the Door Seals and Weather‐stripping.

After the original assessment and in consideration of the unique mission profile of carrying heavy loads of paper, the Leaf Springs were re‐arched and supplemented with an additional Leaf Spring. The van now accommodates any paper loading without bottoming out.

Replacing the Air Conditioner system components restored climate control for the hot Texas summers.

The powertrain was replaced and now carries a 3‐year, 75,000‐mile warranty.

Door replacements and Body repair made the new paint job reset the factory appearance and served as an excellent base for new company graphics in the form of a partial vehicle wrap.