IllustrationRUSTED BRAKE LINE FAILURE, DRIVERS REAR, PASSENGER FRONT, UNDER RADIATIOR. *TR
2002 Chevrolet Avalanche 2500
Owner reports · Recalls · Investigations
Limited comparison data
There is not enough comparable history to draw a useful model-year comparison.
About this comparison →How this year compares
Owner complaints by model year
Compare all Avalanche 2500 years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
00–25K
1025–50K
1250–75K
1875–100K
12100–150K
2150K+
54 reports with mileage · 6 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Engine And Engine Cooling. Review the 28 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Service Brakes. Review the 11 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Service Brakes, Hydraulic. Review the 7 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
3 crash reports2 fire reports1 injury reports
Service Brakes, Hydraulic complaints
7 reportsI WAS DRIVING DOWN THE INTERSTATE ON MY WAY TO WORK, IN MY 2002 CHEVY AVALANCHE, GOING 65 WHEN EVERYONE IN FRONT OF ME SLAMMED ON THEIR BRAKES. I FOLLOWED TO SLAM ON MY BRAKES BUT WHEN I PUSHED THE PEDAL IT WENT STRAIGHT TO THE FLOOR, SO IN ORDER TO NOT REAR END ANYONE I PULLED ONTO THE SHOULDER FLYING PAST THE CARS IN FRONT OF …
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I WAS DRIVING DOWN THE INTERSTATE ON MY WAY TO WORK, IN MY 2002 CHEVY AVALANCHE, GOING 65 WHEN EVERYONE IN FRONT OF ME SLAMMED ON THEIR BRAKES. I FOLLOWED TO SLAM ON MY BRAKES BUT WHEN I PUSHED THE PEDAL IT WENT STRAIGHT TO THE FLOOR, SO IN ORDER TO NOT REAR END ANYONE I PULLED ONTO THE SHOULDER FLYING PAST THE CARS IN FRONT OF ME WITH MY BRAKE PEDAL PUSHED AS HARD AS I COULD, THANKFULLY NO ONE WAS HURT. I DROVE OFF THE RODE AND GOT MY TRUCK TO THE NEAREST GARAGE. WHEN THE GARAGE OWNER LOOKED AT MY BRAKES HE SAID MY REAR BRAKE LINES RUSTED OUT AND THAT THE FRONT WERE ABOUT TO DO THE SAME. HE ALSO SAID THE BRAKE LINES ARE SHOVED SO FAR INTO THE TRUCK FRAME HE WOULD HAVE TO REMOVE THE BODY FROM THE FRAME TO FIX IT PROPERLY. *TR
TL* THE CONTACT OWNS A 2002 CHEVROLET AVALANCHE 2500. THE CONTACT WAS DRIVING 45 MPH WHEN THE BRAKE PEDAL TRAVELED TO THE FLOOR SURFACE WHEN PRESSURE WAS APPLIED. THE EMERGENCY BRAKE WAS ENGAGED TO STOP THE VEHICLE. THERE WAS A MASSIVE LEAK OF BRAKE FLUID. THE CONTACT CONTINUED TO DRIVE WITH EXTREME CAUTION. THE CONTACT NOTICED …
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TL* THE CONTACT OWNS A 2002 CHEVROLET AVALANCHE 2500. THE CONTACT WAS DRIVING 45 MPH WHEN THE BRAKE PEDAL TRAVELED TO THE FLOOR SURFACE WHEN PRESSURE WAS APPLIED. THE EMERGENCY BRAKE WAS ENGAGED TO STOP THE VEHICLE. THERE WAS A MASSIVE LEAK OF BRAKE FLUID. THE CONTACT CONTINUED TO DRIVE WITH EXTREME CAUTION. THE CONTACT NOTICED EXCESSIVE RUST WITHIN THE BRAKE LINE SEVERAL MONTHS BEFORE THE FAILURE. THE MANUFACTURER WAS NOTIFIED AND THEY WERE UNABLE TO PROVIDE ASSISTANCE. THE VEHICLE WAS NEITHER DIAGNOSED FOR THE FAILURE NOR REPAIRED. THE FAILURE MILEAGE WAS 49,123.
COMING UP TO STOP SIGN ON A DOWNHILL BACK ROAD, I EXPERIENCED PARTIAL BRAKE FAILURE FOLLOWED QUICKLY BY COMPLETE BRAKE FAILURE AS I TRIED TO STOP THE VEHICLE. FORTUNATELY, I WAS ONLY DOING 5MPH OR LESS AT THAT POINT BUT I WENT THRU THE STOP SIGN AND HAD TO MAKE AN ABRUPT TURN TO THE RIGHT AND ONTO A SHOULDER TO AVOID HITTING A C…
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COMING UP TO STOP SIGN ON A DOWNHILL BACK ROAD, I EXPERIENCED PARTIAL BRAKE FAILURE FOLLOWED QUICKLY BY COMPLETE BRAKE FAILURE AS I TRIED TO STOP THE VEHICLE. FORTUNATELY, I WAS ONLY DOING 5MPH OR LESS AT THAT POINT BUT I WENT THRU THE STOP SIGN AND HAD TO MAKE AN ABRUPT TURN TO THE RIGHT AND ONTO A SHOULDER TO AVOID HITTING A CAR COMING FROM MY LEFT. AGAIN, I WAS STILL HEADING DOWNHILL AND PICKING UP SPEED. I TRIED TO USE THE EMERGENCY BRAKE BUT IT WASN'T EFFECTIVE MUCH SO I PULLED THE TRANNY DOWN INTO SECOND AND ULTIMATELY DOWN TO FIRST TO GET THE SPEED DOWN. I WAS ABLE TO TURN INTO A LOCAL CUL-DE-SAC WHICH AT FIRST GOES DOWN HILL AND THEN UPHILL. I WAS FINALLY ABLE TO STOP AND FROM THERE I LIMPED THE 1/4 MILE BACK TO MY HOUSE IN FIRST GEAR AND PARK IT. I CALLED AAA FOR A TOW TRUCK AND HAD IT TOWED TO MY MECHANIC. HE REPORTED TO ME THAT THE ENTIRE BRAKE LINE SYSTEM WAS BADLY CORRODED AND ASKED ME IF I PARKED THE VEHICLE A LOT AT THE SEASHORE. I TOLD HIM "NO" BUT I DON'T GARAGE THE VEHICLE EITHER ESPECIALLY DURING THE WINTER. HE SAID THAT HA HAD NEVER SEEN ANYTHING LIKE IT. HE HAD TO REPLACE ALL OF THE BRAKE LINES, HOSES, FITTINGS AND BLEEDER SCREWS. IT COST $1,246.12 AND, YES, HE SHOWED ME ALL OF THE LINES AND PARTS WHICH HE REMOVED---I COULDN'T BELIEVE IT. I CONSIDERED FILING THIS REPORT AT THE TIME BUT #1: I'M A PROCRASTINATOR AND #2 I THOUGHT IT WAS A FLUKE SINCE AGAIN I DON'T GARAGE MY VEHICLE, I DON'T DRIVE IT THAT MUCH ( 50K MILES IN APPROX. 9 YRS) AND I GET A LOT OF SALT ON THE VEHICLE DURING THE WINTER SINCE I LIVE ON A HILL. I'M NOW SORRY FOR NOT REPORTING THIS SOONER SINCE I NO LONGER HAVE THE OLD PARTS OF MY BRAKING SYSTEM AVAILABLE TO ME BUT I FIGURED I BETTER LET YOU KNOW JUST WHAT HAPPENED IN MY CASE BECAUSE I READ A NEWSPAPER ARTICLE ON 04/05/10 THAT SAID YOU WERE LOOKING AT 110 COMPLAINTS OF BRAKE FAILURES IN GENERAL MOTORS SUVS OF ALL SORTS. *TR
ABS BRAKE SYSTEM MALFUNCTIONING --- WHEN SLOWING DOWN TO STOP, AT ABOUT 5MPH, BRAKE PEDAL BECOMES SOFT AND VEHICLE PULLS TO THE RIGHT. RECALL TSB#02-05-25-006B DOES NOT INCLUDE THIS VEHICLE BUT THIS IS THE SAME PROBLEM. LOCAL GM SERVICE DEPT REFUSES TO REPAIR THIS UNSAFE DESIGN DEFECT. *TR
2002 AVALANCHE 2500 4X4 BRAKE LINES ARE FAILING ONE AT A TIME UNDER THE DRIVER SEAT THEIR IS A BRACKET THAT SEEMS TO COLLECT DIRT, SALT , ECT. IN MY OPINION THERE SHOULD BE A RECALL. THIS SHOULD BE STAINLESS BRAKE LINES. I ALMOST GOT KILLED WENT OFF ROAD TO GET STOPPED, TOWED HOME THE TRUCK. NOW THE NEXT PROBLEM IS TRYING TO FI…
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2002 AVALANCHE 2500 4X4 BRAKE LINES ARE FAILING ONE AT A TIME UNDER THE DRIVER SEAT THEIR IS A BRACKET THAT SEEMS TO COLLECT DIRT, SALT , ECT. IN MY OPINION THERE SHOULD BE A RECALL. THIS SHOULD BE STAINLESS BRAKE LINES. I ALMOST GOT KILLED WENT OFF ROAD TO GET STOPPED, TOWED HOME THE TRUCK. NOW THE NEXT PROBLEM IS TRYING TO FIND PARTS ACTUAL 1/4" I.D. WITH METRIC O.D. 10 MM . *TR
TL*THE CONTACT OWNS A 2002 CHEVROLET AVALANCHE 2500. THE CONTACT TOOK THE VEHICLE TO THE REPAIR SHOP FOR ROUTINE MAINTENANCE. THE MECHANIC NOTICED THAT THE ROTORS FAILED AND A REPORT WAS FILED WITH THE MANUFACTURER. THE MANUFACTURER ADVISED THE CONTACT TO TAKE THE VEHICLE TO ONE OF THEIR DEALERS FOR A DIAGNOSIS AND TO CONSIDE…
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TL*THE CONTACT OWNS A 2002 CHEVROLET AVALANCHE 2500. THE CONTACT TOOK THE VEHICLE TO THE REPAIR SHOP FOR ROUTINE MAINTENANCE. THE MECHANIC NOTICED THAT THE ROTORS FAILED AND A REPORT WAS FILED WITH THE MANUFACTURER. THE MANUFACTURER ADVISED THE CONTACT TO TAKE THE VEHICLE TO ONE OF THEIR DEALERS FOR A DIAGNOSIS AND TO CONSIDER IF THEY WOULD ASSIST WITH THE REPAIR. THE CURRENT AND FAILURE MILEAGES WERE 33,000. UPDATED 3/16/09 *CN THE FRONT ROTORS NEEDED TO BE TURNED AND THE REAR PADS NEEDED TO BE REPLACED. UPDATED 03/19/09. *JB
Official recalls
0No recalls in this snapshot.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
3EA11001 · 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
EA07013 · Trailer Hitch Receiver Failure
Opened Sep 14, 2007 · Closed Sep 12, 2008
Status: closed (inferred from source dates) · Trailer Hitches
COMPLAINT REPORTS ALLEGE POOR WELD QUALITY AND/OR BENDING OF THE SUBJECT VEHICLE ORIGINAL EQUIPMENT TRAILER HITCH RECEIVER.THE AGENCY'S INVESTIGATION INCLUDED ANALYSIS OF MANUFACTURER AND AGENCY INCIDENT REPORTS, REVIEW OF POLICE REPORTS, ANALYSIS OF THE AGENCY'S FATAL ANALYSIS REPORTING SYSTEM, A VEHICLE OWNER SURVEY, INSPECTION OF TOW VEHICLES/HITCHES AND ANALYSIS OF FAILED PARTS.INCIDENTS OF WELD FAILURE WERE RARE AND ASSOCIATED WITH VERY LOW-SPEED DRIVING (TURNING, BACKING AND SUDDEN STOPPING).INCIDENTS OF BENDING WERE ASSOCIATED WITH IMPROPER TRAILER HITCH ADJUSTMENT OR OVERLOADING. A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.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 THIS ISSUE AND RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE DOCUMENT SEARCH FILE FOR ADDITION INFORMATION.
PE07025 · Trailer Hitch Receiver Failure
Opened May 14, 2007 · Closed Sep 14, 2007
Status: closed (inferred from source dates) · Trailer Hitches
GM PROVIDED ADDITIONAL DATA REGARDING ALLEGATIONS OF FAILURE OF THE TRAILER HITCH.ODI REVIEWED THAT AS WELL AS OTHER DATA PROVIDED BY PEER MANUFACTURERS.BASED ON OUR REVIEW, ODI FINDS THE NEED TO FURTHER INVESTIGATE THIS ISSUE.THIS PRELIMINARY EVALUATION IS UPGRADED TO AN ENGINEERING ANALYSIS (EA07-013) FOR FURTHER ASSESSMENT AND STUDY OF THIS ISSUE.