NHTSA owner reports · September 18, 2026 snapshot.
Service Brakes, Hydraulic complaints
33 reportsClear category filter70,000 miles · Feb 4, 2016
Service Brakes, Hydraulic
TL* THE CONTACT OWNS A 2002 CHEVROLET AVALANCHE 1500. WHEN APPLYING THE BRAKES, THE BRAKE PEDAL EXTENDED TO THE FLOORBOARD AND FAILED TO STOP THE VEHICLE. THE BRAKE LINES WERE CORRODED. THE VEHICLE WAS PREVIOUSLY REPAIRED FOR THIS FAILURE; HOWEVER, THE FAILURE RECURRED. THE CONTACT TOOK THE VEHICLE TO A CERTIFIED MECHANIC WHO DI…
Read full complaint
TL* THE CONTACT OWNS A 2002 CHEVROLET AVALANCHE 1500. WHEN APPLYING THE BRAKES, THE BRAKE PEDAL EXTENDED TO THE FLOORBOARD AND FAILED TO STOP THE VEHICLE. THE BRAKE LINES WERE CORRODED. THE VEHICLE WAS PREVIOUSLY REPAIRED FOR THIS FAILURE; HOWEVER, THE FAILURE RECURRED. THE CONTACT TOOK THE VEHICLE TO A CERTIFIED MECHANIC WHO DIAGNOSED THAT THE CALIPERS WERE CORRODED. THE BRAKE LINES WERE REPLACED, BUT THE FAILURE WAS NOT REMEDIED. THE APPROXIMATE FAILURE MILEAGE WAS 70,000. UPDATED 04/04/16*LJ
NHTSA ODI #10824241
88,000 miles · Nov 5, 2014
Service BrakesService Brakes, Hydraulic
TL* THE CONTACT OWNS A 2002 CHEVROLET AVALANCHE 1500. THE CONTACT STATED THAT WHILE TRAVELING AT A LOW SPEEDS, THE ABS SENSOR ILLUMINATED AND WHEN APPLYING THE BRAKE PEDAL, THE VEHICLE LUNGED FORWARD. THE CONTACT MENTIONED THAT EXCESSIVE FORCE WAS REQUIRED INTO ORDER TO BRING THE VEHICLE TO A COMPLETE STOP. THE VEHICLE WAS NOT D…
Read full complaint
TL* THE CONTACT OWNS A 2002 CHEVROLET AVALANCHE 1500. THE CONTACT STATED THAT WHILE TRAVELING AT A LOW SPEEDS, THE ABS SENSOR ILLUMINATED AND WHEN APPLYING THE BRAKE PEDAL, THE VEHICLE LUNGED FORWARD. THE CONTACT MENTIONED THAT EXCESSIVE FORCE WAS REQUIRED INTO ORDER TO BRING THE VEHICLE TO A COMPLETE STOP. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER: 05V379000 (SERVICE BRAKES, HYDRAULIC). THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 88,000.
NHTSA ODI #10652714
53,000 miles · Nov 21, 2011
Service Brakes, Hydraulic
TL* THE CONTACT OWNS A 2002 CHEVROLET AVALANCHE 1500. THE CONTACT STATED THAT HE ATTEMPTED TO BRAKE, BUT THE BRAKE PEDAL DEPRESSED TO THE FLOOR. THE CONTACT DOWN SHIFTED AND THE VEHICLE COASTED TO A STOP. THE VEHICLE WAS TAKEN TO A DEALER AND A FIVE FOOT SECTION OF THE BRAKE LINES WAS REPLACED DUE TO CORROSION. THE CONTACT WAS A…
Read full complaint
TL* THE CONTACT OWNS A 2002 CHEVROLET AVALANCHE 1500. THE CONTACT STATED THAT HE ATTEMPTED TO BRAKE, BUT THE BRAKE PEDAL DEPRESSED TO THE FLOOR. THE CONTACT DOWN SHIFTED AND THE VEHICLE COASTED TO A STOP. THE VEHICLE WAS TAKEN TO A DEALER AND A FIVE FOOT SECTION OF THE BRAKE LINES WAS REPLACED DUE TO CORROSION. THE CONTACT WAS ALSO INFORMED THAT THE REMAINDER OF THE BRAKE LINES WOULD NEED TO BE REPLACED DUE TO RUST AND CORROSION. THE FAILURE AND CURRENT MILEAGES WERE 53,000. UPDATED 01/03/12*LJ UPDATED 01/04/12
NHTSA ODI #10436610
87,894 miles · Oct 5, 2011
Service Brakes, Hydraulic
CORROSION OF HARD BRAKE LINE FROM THE MASTER CYLINDER TO THE REAR DISTRIBUTION MODULE RESULTED IN LOSS OF BRAKING CAPACITY WHEN THE BRAKE LINE FAILED RESULTING IN FLUID LEAKAGE. *TR
NHTSA ODI #10428772
67,000 miles · Sep 26, 2011
Service Brakes, Hydraulic
COMING TO A STOP AND BRAKES WENT TO THE FLOOR ABS LIGHT CAME ON , FOUND HOLE IN BRAKE LINE LINES RUSTED ALL THROUGH OUT THE VEHICLE . I ALMOST HIT A WOMEN ON FEB 6 2010 ANOTHER HOLE WAS FOUND IN THE LINE ON SEPT 21 2011 BRAKES DID IT AGAIN TO THE FLOOR IT MY EMERGENCY BRAKE TO STOP 2 DIFFERENT LINES HAVE HOLES IN THEM AM TRYING …
Read full complaint
COMING TO A STOP AND BRAKES WENT TO THE FLOOR ABS LIGHT CAME ON , FOUND HOLE IN BRAKE LINE LINES RUSTED ALL THROUGH OUT THE VEHICLE . I ALMOST HIT A WOMEN ON FEB 6 2010 ANOTHER HOLE WAS FOUND IN THE LINE ON SEPT 21 2011 BRAKES DID IT AGAIN TO THE FLOOR IT MY EMERGENCY BRAKE TO STOP 2 DIFFERENT LINES HAVE HOLES IN THEM AM TRYING TO REPLACE AS MUCH AS I CAN. THERE IS A BOX UNDER THE BODY THAT MY BRAKE LINES GO INTO THEY ARE RUSTED REALLY BAD TO IM NOT SURE WHAT THE BOX IS FOR I HAVE HAD A LOT OF BRAKE PROBLEMS. THIS TRUCK HAS BEEN NOT DRIVEN FOR MONTHS AT A TIME DUE TO BRAKE PROBLEMS THANK YOU. *TR
NHTSA ODI #10427517
83,000 miles · Aug 8, 2011
Service Brakes, Hydraulic
2002 CHEVY AVALANCHE, RUSTED BRAKE LINES, BRAKE LINE BURST(FAILURE), LOSS OF BRAKING. *TR
NHTSA ODI #10417970
92,448 miles · Jun 9, 2011
Service Brakes, Hydraulic
BRAKES FAILED ON 7/12/10 ALMOST REAR ENDED CAR BEFORE CAME TO STOP BY VEERING INTO LEFT LANE TO AVOID CAR STOPPED AT RED LIGHT. REPAIR SHOP REPLACED RUSTED BRAKE LINE. AGAIN, 6/9/11, WENT TO BRAKE FOR RED LIGHT, BRAKE PEDAL WENT TO THE FLOOR AND STOPPED JUST BEFORE REAR ENDING CAR STOPPED AT RED LIGHT. REPAIR SHOP SAYS RUSTED BR…
Read full complaint
BRAKES FAILED ON 7/12/10 ALMOST REAR ENDED CAR BEFORE CAME TO STOP BY VEERING INTO LEFT LANE TO AVOID CAR STOPPED AT RED LIGHT. REPAIR SHOP REPLACED RUSTED BRAKE LINE. AGAIN, 6/9/11, WENT TO BRAKE FOR RED LIGHT, BRAKE PEDAL WENT TO THE FLOOR AND STOPPED JUST BEFORE REAR ENDING CAR STOPPED AT RED LIGHT. REPAIR SHOP SAYS RUSTED BRAKE LINES! *TR
NHTSA ODI #10405811
76,000 miles · Jun 3, 2011
Service Brakes, Hydraulic
TL* THE CONTACT OWNS A 2002 CHEVROLET AVALANCHE 1500. THE CONTACT WAS DRIVING APPROXIMATELY 30 MPH WHEN THE BRAKE WARNING LIGHT ILLUMINATED AND THE BRAKE PEDAL WAS DEPRESSED TO THE FLOOR BOARD, REDUCING BRAKING PRESSURE. THE CONTACT STATED THAT THE FAILURE WAS CONSTANT AND THE BRAKE PEDAL NEEDED TO BE DEPRESSED TO THE FLOOR IN O…
Read full complaint
TL* THE CONTACT OWNS A 2002 CHEVROLET AVALANCHE 1500. THE CONTACT WAS DRIVING APPROXIMATELY 30 MPH WHEN THE BRAKE WARNING LIGHT ILLUMINATED AND THE BRAKE PEDAL WAS DEPRESSED TO THE FLOOR BOARD, REDUCING BRAKING PRESSURE. THE CONTACT STATED THAT THE FAILURE WAS CONSTANT AND THE BRAKE PEDAL NEEDED TO BE DEPRESSED TO THE FLOOR IN ORDER TO STOP THE VEHICLE. THE VEHICLE WAS NOT TAKEN TO A DEALER FOR DIAGNOSTICS OR REPAIRS. THE CONTACT REFERENCED AN OPEN INVESTIGATION RELATING TO THE FAILURE UNDER NHTSA ACTION NUMBER: EA11001 (SERVICE BRAKES, HYDRAULIC SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS). THE APPROXIMATE FAILURE MILEAGE WAS 76,000. UPDATED 08/01/11*LJ UPDATED 08/11/11
NHTSA ODI #10404377
86,830 miles · May 16, 2011
Service Brakes, Hydraulic
TL*THE CONTACT OWNS A 2002 CHEVROLET AVALANCHE 1500. THE CONTACT STATED THAT THE VEHICLE WOULD NOT START IMMEDIATELY; HOWEVER, AFTER SEVERAL ATTEMPTS, THE CONTACT WAS ABLE TO TURN THE VEHICLE ON. THE FAILURE RECURRED THE FOLLOWING DAY. SHE PURCHASED A BATTERY BUT THE VEHICLE WAS MAKING AN UNUSUAL NOISE. SHE ALSO NOTICED THAT TH…
Read full complaint
TL*THE CONTACT OWNS A 2002 CHEVROLET AVALANCHE 1500. THE CONTACT STATED THAT THE VEHICLE WOULD NOT START IMMEDIATELY; HOWEVER, AFTER SEVERAL ATTEMPTS, THE CONTACT WAS ABLE TO TURN THE VEHICLE ON. THE FAILURE RECURRED THE FOLLOWING DAY. SHE PURCHASED A BATTERY BUT THE VEHICLE WAS MAKING AN UNUSUAL NOISE. SHE ALSO NOTICED THAT THE ABS LIGHT ILLUMINATED ON THE INSTRUMENT PANEL. SHE TURNED THE VEHICLE OFF BUT THE NOISE CONTINUED. WHEN SHE TRIED TO START THE VEHICLE THE FOLLOWING DAY, THE BATTERY WAS DEAD. THE DEALER ADVISED HER TO UNPLUG THE ABS MOTOR. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHO STATED THAT THE ABS MOTOR NEEDED TO BE REPLACED. THE VEHICLE HAD NOT BEEN REPAIRED. THE MANUFACTURER STATED THAT THE VEHICLE WAS NOT INCLUDED IN RECALL 05V379000 (SERVICE BRAKES, HYDRAULIC:ANTILOCK). THE CURRENT MILEAGE WAS 86,835. THE FAILURE MILEAGE WAS 86,830.
NHTSA ODI #10401129
160,000 miles · Feb 20, 2011
Service Brakes, Hydraulic
2002 CHEVROLET AVALANCHE Z-71, BRAKE LINES RUSTY TO THE POINT OF FAILURE AT ANYTIME, SPONGY PEDAL, AND DIFFICULTY STOPPING. AT PRESENT TIME HAVE NOT REPAIRED DUE TO EXTREME COST. IF THERE IS A CATASTROPHIC FAILURE OF THE BRAKE SYSTEM THERE WILL BE A MASSIVE CLASS ACTION LAW SUIT (IF MY FAMILY AND I SURVIVE). *TR
NHTSA ODI #10383363
NHTSA investigations
1EA11001 · Brake Line Corrosion Failure
Opened Jan 5, 2011 · Closed Apr 8, 2015
Status: closed (inferred from source dates) · Service Brakes, Hydraulic; Service Brakes, Hydraulic:foundation Components:hoses, Lines/piping, And Fittings
On January 11, 2011, ODI opened EA11-001 to investigate allegations of premature brake line corrosion failure in model year (MY) 1999 through 2003 General Motors (GM) full-size pickup trucks and sport utility vehicles sold or registered in the following region of the United States that NHTSA has viewed as salt states for investigations of corrosion related issues:Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia and Wisconsin.The subject vehicles represent the first five MY's of GM's GMT800 platform production, of which approximately 2,038,504 vehicles were sold in salt states (the subject vehicles).The GMT800 platform includes the following vehicles:1999-2007 Chevrolet Silverado and GMC Sierra 1500, 2500 and 3500 series pick-up trucks; 2000-2006 Chevrolet Suburban, Chevrolet Tahoe and GMC Yukon sport utility vehicles; and 2002-2006 Cadillac Escalade and Chevrolet Avalanche sport-utility vehicles.General Motors produced a total of approximately 10,427,062 GMT800 vehicles for sales in the United States, including almost 5 million that were sold in salt states.Although there are over 60 different brake pipe routing configuration used in GMT800 vehicles, with the exception of the rear crossover pipes in MY 200x-2007 vehicles that changed from rear disc to drum brakes, all of the vehicles use brake pipes from the same supplier with a common double-wall, brazed steel pipe design with a combination of hot dip Zinc-Aluminum corrosion protection coating and Aluminum paint outer layer known in the industry as AlGal (ASTM-B750). ODI analysis of field data regarding GMT800 vehicles identified a total of 3,645 complaints of brake pipe corrosion failures, including 107 alleging crashes, and 40 injuries.Though only 20% of total GMT800 production, due to age and region the subject vehicles account for a disproportionate share of the failure experience; with 2,702 of the complaints (75%), 88 of the crashes (82%) and 20 of the injuries (50%) reported in those vehicles.Analysis of the complaints showed strong correlations to vehicle age and region.For vehicles with less than 8 years of service, the complaint rates were minimal for all regions.In the salt states the failure rates begin to climb as the vehicles advance in age, particularly in the Northeast corner of the United States.The complaint rates in the salt states go from less than 0.1 incident per thousand vehicles (IPTV) at 7 years in service to over 1.0 IPTV after the 12th year of service for the subject pickup trucks and utility vehicles.Most of the failures reported to ODI occurred in vehicles with more than 10 years in service.ODI?s investigation did not identify any specific defect conditions that were causing or contributing to the brake pipe failures.Nor did the analysis isolate the problem to any subject vehicle sub-populations when analyzed by vehicle type or production range.The investigation found that vehicles experiencing brake pipe corrosion failures were likely to have general patterns of excessive corrosion on the majority of the brake pipe assembly and appear to be occurring due to expected wear out for the brake pipe coating material used in the subject vehicles and the environmental conditions in severe corrosion states.A safety-related defect has not been identified at this time.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor t
Additional source detail variants (2)
Service Brakes, Hydraulic:foundation Components:hoses, Lines/piping, And Fittings
On January 11, 2011, ODI opened EA11-001 to investigate allegations of premature brake line corrosion failure in model year (MY) 1999 through 2003 General Motors (GM) full-size pickup trucks and sport utility vehicles sold or registered in the following region of the United States that NHTSA has viewed as salt states for investigations of corrosion related issues:Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia and Wisconsin.The subject vehicles represent the first five MY's of GM's GMT800 platform production, of which approximately 2,038,504 vehicles were sold in salt states (the subject vehicles).The GMT800 platform includes the following vehicles:1999-2007 Chevrolet Silverado and GMC Sierra 1500, 2500 and 3500 series pick-up trucks; 2000-2006 Chevrolet Suburban, Chevrolet Tahoe and GMC Yukon sport utility vehicles; and 2002-2006 Cadillac Escalade and Chevrolet Avalanche sport-utility vehicles.General Motors produced a total of approximately 10,427,062 GMT800 vehicles for sales in the United States, including almost 5 million that were sold in salt states.Although there are over 60 different brake pipe routing configuration used in GMT800 vehicles, with the exception of the rear crossover pipes in MY 200x-2007 vehicles that changed from rear disc to drum brakes, all of the vehicles use brake pipes from the same supplier with a common double-wall, brazed steel pipe design with a combination of hot dip Zinc-Aluminum corrosion protection coating and Aluminum paint outer layer known in the industry as AlGal (ASTM-B750). ODI analysis of field data regarding GMT800 vehicles identified a total of 3,645 complaints of brake pipe corrosion failures, including 107 alleging crashes, and 40 injuries.Though only 20% of total GMT800 production, due to age and region the subject vehicles account for a disproportionate share of the failure experience; with 2,702 of the complaints (75%), 88 of the crashes (82%) and 20 of the injuries (50%) reported in those vehicles.Analysis of the complaints showed strong correlations to vehicle age and region.For vehicles with less than 8 years of service, the complaint rates were minimal for all regions.In the salt states the failure rates begin to climb as the vehicles advance in age, particularly in the Northeast corner of the United States.The complaint rates in the salt states go from less than 0.1 incident per thousand vehicles (IPTV) at 7 years in service to over 1.0 IPTV after the 12th year of service for the subject pickup trucks and utility vehicles.Most of the failures reported to ODI occurred in vehicles with more than 10 years in service.ODI?s investigation did not identify any specific defect conditions that were causing or contributing to the brake pipe failures.Nor did the analysis isolate the problem to any subject vehicle sub-populations when analyzed by vehicle type or production range.The investigation found that vehicles experiencing brake pipe corrosion failures were likely to have general patterns of excessive corrosion on the majority of the brake pipe assembly and appear to be occurring due to expected wear out for the brake pipe coating material used in the subject vehicles and the environmental conditions in severe corrosion states.A safety-related defect has not been identified at this time.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor t
Service Brakes, Hydraulic
On January 11, 2011, ODI opened EA11-001 to investigate allegations of premature brake line corrosion failure in model year (MY) 1999 through 2003 General Motors (GM) full-size pickup trucks and sport utility vehicles sold or registered in the following region of the United States that NHTSA has viewed as salt states for investigations of corrosion related issues:Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia and Wisconsin.The subject vehicles represent the first five MY's of GM's GMT800 platform production, of which approximately 2,038,504 vehicles were sold in salt states (the subject vehicles).The GMT800 platform includes the following vehicles:1999-2007 Chevrolet Silverado and GMC Sierra 1500, 2500 and 3500 series pick-up trucks; 2000-2006 Chevrolet Suburban, Chevrolet Tahoe and GMC Yukon sport utility vehicles; and 2002-2006 Cadillac Escalade and Chevrolet Avalanche sport-utility vehicles.General Motors produced a total of approximately 10,427,062 GMT800 vehicles for sales in the United States, including almost 5 million that were sold in salt states.Although there are over 60 different brake pipe routing configuration used in GMT800 vehicles, with the exception of the rear crossover pipes in MY 200x-2007 vehicles that changed from rear disc to drum brakes, all of the vehicles use brake pipes from the same supplier with a common double-wall, brazed steel pipe design with a combination of hot dip Zinc-Aluminum corrosion protection coating and Aluminum paint outer layer known in the industry as AlGal (ASTM-B750). ODI analysis of field data regarding GMT800 vehicles identified a total of 3,645 complaints of brake pipe corrosion failures, including 107 alleging crashes, and 40 injuries.Though only 20% of total GMT800 production, due to age and region the subject vehicles account for a disproportionate share of the failure experience; with 2,702 of the complaints (75%), 88 of the crashes (82%) and 20 of the injuries (50%) reported in those vehicles.Analysis of the complaints showed strong correlations to vehicle age and region.For vehicles with less than 8 years of service, the complaint rates were minimal for all regions.In the salt states the failure rates begin to climb as the vehicles advance in age, particularly in the Northeast corner of the United States.The complaint rates in the salt states go from less than 0.1 incident per thousand vehicles (IPTV) at 7 years in service to over 1.0 IPTV after the 12th year of service for the subject pickup trucks and utility vehicles.Most of the failures reported to ODI occurred in vehicles with more than 10 years in service.ODI?s investigation did not identify any specific defect conditions that were causing or contributing to the brake pipe failures.Nor did the analysis isolate the problem to any subject vehicle sub-populations when analyzed by vehicle type or production range.The investigation found that vehicles experiencing brake pipe corrosion failures were likely to have general patterns of excessive corrosion on the majority of the brake pipe assembly and appear to be occurring due to expected wear out for the brake pipe coating material used in the subject vehicles and the environmental conditions in severe corrosion states.A safety-related defect has not been identified at this time.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor t
Illustration