NHTSA owner reports · September 18, 2026 snapshot.
Fuel System, Gasoline complaints
9 reportsClear category filter114,171 miles · Jul 15, 2014
Fuel System, GasolineService Brakes
DURING COMMUTE TO WORK ON 22 APRIL 2014, AS I WAS APPROACHING A STOPLIGHT AND PRESSED THE BRAKES TO SLOW DOWN, THE MAIN CONSOLE CHIMED, SHOWED A MESSAGE TO CHECK BRAKES, AND I WAS ABLE TO PRESS THE BRAKE LEVER TO THE FLOOR. I WAS STILL ABLE TO STOP PRIOR TO REACHING THE STOPLIGHT. I SLOWLY RETURNED HOME (ABOUT A MILE) AND WAS …
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DURING COMMUTE TO WORK ON 22 APRIL 2014, AS I WAS APPROACHING A STOPLIGHT AND PRESSED THE BRAKES TO SLOW DOWN, THE MAIN CONSOLE CHIMED, SHOWED A MESSAGE TO CHECK BRAKES, AND I WAS ABLE TO PRESS THE BRAKE LEVER TO THE FLOOR. I WAS STILL ABLE TO STOP PRIOR TO REACHING THE STOPLIGHT. I SLOWLY RETURNED HOME (ABOUT A MILE) AND WAS ABLE TO STOP THE TRUCK NEARBY, THOUGH THE BRAKES WERE NO LONGER ABLE TO STOP THE VEHICLE WHILE IN DRIVE. WHEN PLACED ON THE FLATBED TOW TRUCK, THE DRIVER NOTICED THAT THE BRAKE FLUID WAS LEAKING ONTO THE BED. AT THE DEALERSHIP, THE MECHANICS STATED THE BRAKE LINES WERE CORRODED AND THE ENTIRE SYSTEM NEEDED TO BE REPLACED BEHIND THE MASTER CYLINDER. ADDITIONALLY, I HAD ASKED THEM TO INSPECT WHY I SOMETIMES HAD DIFFICULTY STARTING THE VEHICLE WHICH WAS DIAGNOSED AS A FAULTY FUEL PUMP. THIS COULD NOT BE REMOVED FROM THE FUEL TANK (DUE TO CORROSION), AND I WAS FORCED TO REPLACE THE ENTIRE TANK SYSTEM TO REPLACE THE PUMP. *TR
NHTSA ODI #10610588
42,971 miles · May 24, 2014
Fuel System, GasolineService Brakes
I APPROACHED AN INTERSECTION WHERE MY TRAFFIC LIGHT SIGNAL WAS RED AND I HAD SUDDEN LOSS OF BRAKING IN MY 2003 SILVERADO C1500, WITH NO PRIOR INDICATION OR WARNING LIGHTS. THE BRAKE PEDAL WENT VERY LOW AND I COULD NOT STOP MY VEHICLE BEFORE ENTERING THE INTERSECTION. I STEERED TO THE RIGHT OF TWO WAITING CARS IN FRONT OF ME AND …
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I APPROACHED AN INTERSECTION WHERE MY TRAFFIC LIGHT SIGNAL WAS RED AND I HAD SUDDEN LOSS OF BRAKING IN MY 2003 SILVERADO C1500, WITH NO PRIOR INDICATION OR WARNING LIGHTS. THE BRAKE PEDAL WENT VERY LOW AND I COULD NOT STOP MY VEHICLE BEFORE ENTERING THE INTERSECTION. I STEERED TO THE RIGHT OF TWO WAITING CARS IN FRONT OF ME AND CAME TO A STOP IN THE INTERSECTION BEYOND THE LIGHT. FORTUNATELY THERE WERE NO VEHICLES COMING AT THAT MOMENT ON THE 4 LANE HIGHWAY CROSSROAD SO A CRASH WAS AVOIDED. ALL OF THE BRAKE AND FUEL LINES WERE INSPECTED AFTER THE INCIDENT AND FOUND TO BE HEAVILY CORRODED (RUSTED), WITH THE REAR BRAKE LINE LEAKING ABOUT 2 INCHES FROM WHERE IT EXITS THE ABS UNIT UNDER THE CAB. THE MASTER CYLINDER FLUID LEVEL WAS NORMAL AND THERE WERE NEVER ANY PREVIOUS LEAKS, WARNING LIGHTS, OR PROBLEMS LIKE THIS AND I AM THE ORIGINAL VEHICLE OWNER. THE VISIBLE LEVEL OF CORROSION SEEMS EXTREME ON THE BRAKE AND FUEL LINES ON THIS VEHICLE. HAD I BEEN IN AN ACCIDENT, I WOULD BE CONCERNED THAT FUEL LINES COULD ALSO LEAK AND INCREASE THE LIKELIHOOD OF A FIRE DUE TO THEIR LIKEWISE POOR CONDITION DUE TO EXTREME RUST. *TR
NHTSA ODI #10593911
153,390 miles · Dec 6, 2013
Fuel System, GasolineService BrakesVehicle Speed Control
MY WIFE WAS DRIVING OUR 2003 CHEVROLET SILVERADO 4X4 PICKUP ON SECONDARY STATE ROUTE. WHILE DESCENDING AN APPROXIMATE 6% GRADE INTO A RIGHT HAND TURN AT BOTTOM SHE DEPRESSED THE BRAKE PEDAL TO SLOW FOR THE GRADE AND TURN AND IT WENT TO THE FLOOR, THE SERVICE BRAKE MESSAGE CAME UP IN THE DIC AND THE DOOR CHIME SOUNDED. SHE PULL…
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MY WIFE WAS DRIVING OUR 2003 CHEVROLET SILVERADO 4X4 PICKUP ON SECONDARY STATE ROUTE. WHILE DESCENDING AN APPROXIMATE 6% GRADE INTO A RIGHT HAND TURN AT BOTTOM SHE DEPRESSED THE BRAKE PEDAL TO SLOW FOR THE GRADE AND TURN AND IT WENT TO THE FLOOR, THE SERVICE BRAKE MESSAGE CAME UP IN THE DIC AND THE DOOR CHIME SOUNDED. SHE PULLED OVER AS SOON AS POSSIBLE AS SHE WAS SHAKEN FROM RIDING OUT THAT HILL AND TURN WITH MINIMAL BRAKES AND CALLED ME. I WENT OUT AND DROVE THE TRUCK BACK TO OUR HOME AND PUT IN THE GARAGE TO INSPECT THE PROBLEM. ONCE UNDER THE TRUCK I FOUND BRAKE FLUID DRIPPING FROM THE SIDE OF THE FUEL TANK AND FRAME AREA UNDER THE CAB AND BED OF THE TRUCK. THE SERVICE BRAKE LINE FROM THE ABS BLOCK TO THE REAR FRAME POINT WHERE THE BRAKE HOSE TO THE REAR AXLE MOUNTS WAS CORRODED THROUGH AND LEAKING. FURTHER INSPECTION SHOWED ALL BRAKE HARD LINE PLUMBING TO BE IN POOR CONDITION AND ALSO THE FUEL LINES SHOWING HIGH CORROSION. A CALL TO A LOCAL GM PARTS COUNTER REVEALED THAT GM DOES NOT MAKE A REPLACEMENT SET FOR THESE LINES AND THAT A TECHNICIAN WOULD NEED TO FIELD BEND AND MAKE UP EACH LINE. LATER RESEARCH PROVED THIS TO BE WRONG AS GM OFFERS A DEEPLY DISCOUNTED UNADVERTISED LINE SET FROM AC DELCO. IN RESEARCHING FINDING PARTS TO REPAIR, I HAVE FOUND THIS TO BE A COMMON PROBLEM WITH CHEVROLET/GMC TRUCKS FROM ABOUT 1999 UP ACCORDING TO THE VARIOUS TRUCK OWNER FORUMS ONLINE. DRIVING THE VEHICLE HOME AT SLOW SPEED, BRAKING WAS VERY MINIMAL WITH THE REAR BRAKE CIRCUIT OUT,AND THE KNOWLEDGE OF POOR BRAKE OPERATION, SO THEREFORE IT IS MY OPINION THAT THIS IS A SAFETY ISSUE WITH THESE VEHICLES WITH THE POTENTIAL OF INJURY OR EVEN DEATH WHEN ALL THE FACTORS COMBINE POORLY, AND AT THE LEAST, GM SHOULD BE REQUIRED TO NOTIFY OWNERS OF THIS POTENTIAL PROBLEM WITH THEIR VEHICLE, IF NOT RECALL AND REPAIR THOSE EFFECTED VEHICLES. *TR
NHTSA ODI #10555068
137,882 miles · Nov 11, 2013
Fuel System, GasolineService BrakesStructure
WELL ABOUT MID 2012 THE BRAKE LINES JUST RUST OUT IN THE MIDDLE OF THE TRUCK AND THE REAR. MY GIRL FRIEND WAS DRIVING IT TO WORK AND LOST ALL THE PEDAL PRESSURE. THANK GOD SHE WAS GOING UP IN THE PARKING GARAGE. RIGHT NOW I'M TRYING TO REPLACE LINE FUEL LINES. IT JUST STARTED POURING GAS OUT AFTER I JUST GOT TO WORK. I NURSED I…
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WELL ABOUT MID 2012 THE BRAKE LINES JUST RUST OUT IN THE MIDDLE OF THE TRUCK AND THE REAR. MY GIRL FRIEND WAS DRIVING IT TO WORK AND LOST ALL THE PEDAL PRESSURE. THANK GOD SHE WAS GOING UP IN THE PARKING GARAGE. RIGHT NOW I'M TRYING TO REPLACE LINE FUEL LINES. IT JUST STARTED POURING GAS OUT AFTER I JUST GOT TO WORK. I NURSED IT HOME AND MADE IT. THE RETURN LINE IS JUST ALL RUSTED OUT. THEN I NOTICED ALL THREE LINES WHERE ALL RUSTED OUT. IT'S TO BAD NOTHING HAS BEEN DONE YET I CAN'T AFFORD THIS! IT IS WELL KNOWN AND UNDERSTOOD BY MANY THAT THIS IS A BIG PROBLEM. ALSO TO TOP THAT THE FRAME LOOKS MORE RUSTED THAN THE 1989 DODGE I JUST GOT RIDE OF. I WASH UNDER THE TRUCK THROUGH OUT WINTER AND DON'T UNDERSTAND WHY IT'S SO BAD ALREADY. *TR
NHTSA ODI #10551832
116,000 miles · Feb 4, 2013
Fuel System, GasolineService Brakes, Hydraulic
HAD HOOKED TRUCK TO A CAR TRAILER AND STEPPED ON BRAKES TO PUT TRUCK IN DRIVE AND BRAKE PEDAL WENT TO FLOOR, THERE WAS NO BRAKES AT ALL. UPON EXAMINING I FOUND THAT THREE BRAKE LINES HAD FAILED. THE TRUCK WAS TOWED TO A LOCAL GARAGE AND THEY FOUND THAT ALL BRAKE LINES AND ALSO THE FUEL LINES WERE BADLY RUSTED AND HAD TO BE REPLA…
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HAD HOOKED TRUCK TO A CAR TRAILER AND STEPPED ON BRAKES TO PUT TRUCK IN DRIVE AND BRAKE PEDAL WENT TO FLOOR, THERE WAS NO BRAKES AT ALL. UPON EXAMINING I FOUND THAT THREE BRAKE LINES HAD FAILED. THE TRUCK WAS TOWED TO A LOCAL GARAGE AND THEY FOUND THAT ALL BRAKE LINES AND ALSO THE FUEL LINES WERE BADLY RUSTED AND HAD TO BE REPLACED.
NHTSA ODI #10497241
89,000 miles · Sep 28, 2012
Fuel System, GasolineService BrakesStructure
WAS ATTEMPTING TO BACK VEHICLE AND CAMPER TRAILER DOWN INCLINED DRIVEWAY WHEN SUDDENLY THE BRAKE PEDAL WENT COMPLETELY TO THE FLOOR AND I HAD ABSOLUTE MINIMUM BRAKING FORCE. WAS ABLE TO STOP VEHICLE BEFORE IT AND TRAILER WENT OVER THE HILL, (AN APPROXIMATE 15 - 20 FOOT DROP IF IT HAD OCCURRED). UPON INSPECTION I FOUND BRAKE FL…
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WAS ATTEMPTING TO BACK VEHICLE AND CAMPER TRAILER DOWN INCLINED DRIVEWAY WHEN SUDDENLY THE BRAKE PEDAL WENT COMPLETELY TO THE FLOOR AND I HAD ABSOLUTE MINIMUM BRAKING FORCE. WAS ABLE TO STOP VEHICLE BEFORE IT AND TRAILER WENT OVER THE HILL, (AN APPROXIMATE 15 - 20 FOOT DROP IF IT HAD OCCURRED). UPON INSPECTION I FOUND BRAKE FLUID ON THE DRIVEWAY. UPON FURTHER INSPECTION I DISCOVERED THAT A BRAKE LINE LEADING FROM THE MASTER CYLINDER TO THE ABS CONTROLLER WAS LEAKING. UPON FURTHER INSPECTION I FOUND THAT ALL THE BRAKE LINES WERE SEVERELY CORRODED AND READY TO FAIL. I CANNOT BELIEVE HOW MUCH RUST IS PRESENT ON THE BRAKE LINES AND THE FUEL LINES. THIS APPEARS TO BE A MAJOR ACCIDENT WAITING TO HAPPEN. *TR
NHTSA ODI #10477437
100,000 miles · Jul 2, 2012
Fuel System, GasolineService BrakesService Brakes, Hydraulic
UPON STARTING THE VEHICLE AND DEPRESSING THE BRAKES, THE BRAKES WENT TO THE FLOOR. UPON INSPECTION FROM A MECHANIC, IT WAS NOTED THAT BOTH BRAKE LINES WERE ROTTED (ONE WAS ROTTED ALL THE WAY THROUGH CAUSING THE FLUID TO LEAK FROM THE LINE). WE WERE ALSO TOLD THAT THE GAS LINE AND CALIPER HAD SEVERE ROTTING. UPON MY RESEARCH, THI…
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UPON STARTING THE VEHICLE AND DEPRESSING THE BRAKES, THE BRAKES WENT TO THE FLOOR. UPON INSPECTION FROM A MECHANIC, IT WAS NOTED THAT BOTH BRAKE LINES WERE ROTTED (ONE WAS ROTTED ALL THE WAY THROUGH CAUSING THE FLUID TO LEAK FROM THE LINE). WE WERE ALSO TOLD THAT THE GAS LINE AND CALIPER HAD SEVERE ROTTING. UPON MY RESEARCH, THIS SEEMS TO BE A VERY COMMON PROBLEM WITH CHEVROLET TRUCKS. I HOPE THIS WILL BE RESOLVED SO ADDITIONAL CHEVROLET OWNERS DO NOT HAVE SEVERE ACCIDENTS DUE TO THESE ISSUES. MY HUSBAND AND 4 YEAR OLD SON HAD TO WALK QUITE A FEW MILES IN 95 DEGREE WEATHER! THIS IS A SAFETY ISSUE AND I HOPE MY COMPLAINT WILL HELP FURTHER THE INVESTIGATION. *JS *TR
NHTSA ODI #10464021
150,000 miles · Feb 9, 2010
Fuel System, Gasoline
CHEVY SILVERADO 5.3 L ENGINE. REDUCED ENGINE POWER MESSAGE IS DISPLAYED. VEHICLE WILL NOT RUN ABOVE 20 MPH. MUST PULL OVER AND TURN OFF ENGINE AND RESTART. THIS IS A KNOWN PROBLEM BY GM. DEALER TRIED TWICE TO REPAIR THE PROBLEM BUT COULD NOT. I REPLACED THE ACCELERATOR SENSOR AND THE THROTTLE BODY BUT THE PROBLEM STILL EXI…
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CHEVY SILVERADO 5.3 L ENGINE. REDUCED ENGINE POWER MESSAGE IS DISPLAYED. VEHICLE WILL NOT RUN ABOVE 20 MPH. MUST PULL OVER AND TURN OFF ENGINE AND RESTART. THIS IS A KNOWN PROBLEM BY GM. DEALER TRIED TWICE TO REPAIR THE PROBLEM BUT COULD NOT. I REPLACED THE ACCELERATOR SENSOR AND THE THROTTLE BODY BUT THE PROBLEM STILL EXISTS. THIS IS VERY DANGEROUS WHEN IT HAPPENS ON THE HIGHWAY. THIS HAS BEEN GOING ON WITH MY TRUCK FOR ABOUT 18 MONTHS. AGAIN, NO SUPPORT FROM GM. MANY PEOPLE ARE HAVING THIS PROBLEM. THERE SHOULD BE A RECALL. *TR
NHTSA ODI #10307734
13,104 miles · Feb 7, 2010
Fuel System, GasolineFuel System, Other
JUST BOUGHT A 2003 CHEVY SILVERADO 4X4 WITH A 5.3LT ENGINE . PROBLEMS WITH THE FUEL GAUGE, IT WORKED WHEN TEST DROVE AT DEALER AND AFTER BUYING THE TRUCK IT STOPPED ON THE WAY HOME!!!! BEEN TOLD IT WILL COST HUNDREDS TO FIX !!!! AFTER RESEARCHING ON THE NET I HAVE FOUND THAT THIS IS A COMMON PROBLEM WITH GM TRUCKS,AND NOT ONLY W…
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JUST BOUGHT A 2003 CHEVY SILVERADO 4X4 WITH A 5.3LT ENGINE . PROBLEMS WITH THE FUEL GAUGE, IT WORKED WHEN TEST DROVE AT DEALER AND AFTER BUYING THE TRUCK IT STOPPED ON THE WAY HOME!!!! BEEN TOLD IT WILL COST HUNDREDS TO FIX !!!! AFTER RESEARCHING ON THE NET I HAVE FOUND THAT THIS IS A COMMON PROBLEM WITH GM TRUCKS,AND NOT ONLY WITH 2003 TRUCKS BUT MANY OF OTHER YEARS!!!!!!!! AND ALSO SOME CAR MODELS NOW WITH ALL THE PROBLEMS PEOPLE ARE HAVING THIS CANNOT BE A COINCIDENCE!! IF YOU WANT PROOF JUST READ THE GM FORUMS IT'S AMAZING HOW MANY PEOPLE ARE HAVING GAS GAUGE PROBLEMS !!!!!!!!! I DO NOT UNDERSTAND WHY THERE IS NOT A RECALL ON THIS, AS WELL AS ALL THE PEOPLE ON A NUMBER OF GM CHAT FORUMS, EVERYONE IS WONDERING WHY GM (GOVERNMENT MOTORS)HAVE NOT SENT OUT A RECALL EITHER !!!!!!!! I DID NOT BUY A TRUCK FOR THOUSANDS SO I COULD TURN AROUND AND SPEND HUNDREDS TO GET IT FIXED, WHEN IT'S ACTUALLY A DESIGN PROBLEM !!!!!!!! THEY DO A RECALL FOR THE GM TAILGATES BUT NOT FOR SOMETHING AS IMPORTANT AS A FUEL GAUGE ?!?!?!?!?! DO SOME RESEARCH AND YOU WILL UNDERSTAND WHAT I AM TALKING ABOUT !!! THANKS FOR YOUR TIME AND I HOPE SOMETHING CAN BE DONE ABOUT THIS EXPENSIVE PROBLEM SOON. *TW
NHTSA ODI #10307302
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
EA04011 · Parking Brake Failure
Opened Apr 9, 2004 · Closed May 10, 2005
Status: closed (inferred from source dates) · Parking Brake; Parking Brake:conventional; Parking Brake:conventional:mechanical; Parking Brake:conventional:mechanical:linkage And Cable
IN A LETTER DATED APRIL 20, 2005, GM NOTIFIED NHTSA THAT IT HAD DECIDED THAT DEFECTS THAT RELATE TO MOTOR VEHICLE SAFETY EXIST IN CERTAIN MODEL YEAR (MY) 1999-2002 C/K 1500 SERIES (PBR PARKING BRAKE SYSTEM) AND MY 2001-2005 C/K 2500 AND 3500 SERIES (TRW PARKING BRAKE SYSTEM) PICKUPS WITH MANUAL TRANSMISSIONS.ACCORDING TO GM, SOME OF THESE VEHICLES MAY HAVE CONDITIONS THAT CAUSE THE FRICTION LININGS TO WEAR TO AN EXTENT WHERE THE PARKING BRAKE CAN BECOME INEFFECTIVE IN IMMOBILIZING A PARKED VEHICLE.GM'S ACTION COVERS AN ESTIMATED TOTAL OF 142,585 VEHICLES.DEALERS WILL INSTALL A LOW-FORCE SPRING CLIP RETAINER FOR VEHICLES EQUIPPED WITH THE PBR PARKING BRAKE SYSTEM AND INSTALL A REDESIGNED PARKING BRAKE CABLE ASSEMBLY ON VEHICLES EQUIPPED WITH THE TRW PARKING BRAKE SYSTEM. A TOTAL OF 58 NON-DUPLICATIVE COMPLAINTS WERE RECEIVED BY ODI AND GM CONCERNING THE APPROXIMATELY 59,000 MY 1999-2002 C/K 1500 SERIES PICKUP TRUCKS WITH THE PBR PARKING BRAKE SYSTEM.THESE INCLUDED 22 ALLEGED ROLLAWAY INCIDENTS, RESULTING IN A RATE OF 38.5 ROLLAWAY INCIDENTS PER 100,000 VEHICLES.ODI IS AWARE OF 24 COMPLAINTS REGARDING THE MY 2001-2005 C/K 2500 AND 3500 SERIES MANUAL TRANSMISSION TRUCKS RECALLED BY GM, INCLUDING 5 ALLEGING ROLLAWAY INCIDENTS.THOUGH THE CONDITIONS DESCRIBED IN GM'S LETTER ARE ALSO PRESENT IN THE C/K TRUCKS WITH AUTOMATIC TRANSMISSIONS, THE ROLLAWAY RATE IN THOSE VEHICLES WAS SIMILAR TO THOSE OBSERVED IN PEER VEHICLES STUDIED BY ODI IN THIS INVESTIGATION.THIS ENGINEERING ANALYSIS IS CLOSED. FOR ADDITIONAL INFORMATION, SEE THE ATTACHED CLOSING REPORT.
Additional source detail variants (4)
Parking Brake:conventional
IN A LETTER DATED APRIL 20, 2005, GM NOTIFIED NHTSA THAT IT HAD DECIDED THAT DEFECTS THAT RELATE TO MOTOR VEHICLE SAFETY EXIST IN CERTAIN MODEL YEAR (MY) 1999-2002 C/K 1500 SERIES (PBR PARKING BRAKE SYSTEM) AND MY 2001-2005 C/K 2500 AND 3500 SERIES (TRW PARKING BRAKE SYSTEM) PICKUPS WITH MANUAL TRANSMISSIONS.ACCORDING TO GM, SOME OF THESE VEHICLES MAY HAVE CONDITIONS THAT CAUSE THE FRICTION LININGS TO WEAR TO AN EXTENT WHERE THE PARKING BRAKE CAN BECOME INEFFECTIVE IN IMMOBILIZING A PARKED VEHICLE.GM'S ACTION COVERS AN ESTIMATED TOTAL OF 142,585 VEHICLES.DEALERS WILL INSTALL A LOW-FORCE SPRING CLIP RETAINER FOR VEHICLES EQUIPPED WITH THE PBR PARKING BRAKE SYSTEM AND INSTALL A REDESIGNED PARKING BRAKE CABLE ASSEMBLY ON VEHICLES EQUIPPED WITH THE TRW PARKING BRAKE SYSTEM. A TOTAL OF 58 NON-DUPLICATIVE COMPLAINTS WERE RECEIVED BY ODI AND GM CONCERNING THE APPROXIMATELY 59,000 MY 1999-2002 C/K 1500 SERIES PICKUP TRUCKS WITH THE PBR PARKING BRAKE SYSTEM.THESE INCLUDED 22 ALLEGED ROLLAWAY INCIDENTS, RESULTING IN A RATE OF 38.5 ROLLAWAY INCIDENTS PER 100,000 VEHICLES.ODI IS AWARE OF 24 COMPLAINTS REGARDING THE MY 2001-2005 C/K 2500 AND 3500 SERIES MANUAL TRANSMISSION TRUCKS RECALLED BY GM, INCLUDING 5 ALLEGING ROLLAWAY INCIDENTS.THOUGH THE CONDITIONS DESCRIBED IN GM'S LETTER ARE ALSO PRESENT IN THE C/K TRUCKS WITH AUTOMATIC TRANSMISSIONS, THE ROLLAWAY RATE IN THOSE VEHICLES WAS SIMILAR TO THOSE OBSERVED IN PEER VEHICLES STUDIED BY ODI IN THIS INVESTIGATION.THIS ENGINEERING ANALYSIS IS CLOSED. FOR ADDITIONAL INFORMATION, SEE THE ATTACHED CLOSING REPORT.
Parking Brake:conventional:mechanical
IN A LETTER DATED APRIL 20, 2005, GM NOTIFIED NHTSA THAT IT HAD DECIDED THAT DEFECTS THAT RELATE TO MOTOR VEHICLE SAFETY EXIST IN CERTAIN MODEL YEAR (MY) 1999-2002 C/K 1500 SERIES (PBR PARKING BRAKE SYSTEM) AND MY 2001-2005 C/K 2500 AND 3500 SERIES (TRW PARKING BRAKE SYSTEM) PICKUPS WITH MANUAL TRANSMISSIONS.ACCORDING TO GM, SOME OF THESE VEHICLES MAY HAVE CONDITIONS THAT CAUSE THE FRICTION LININGS TO WEAR TO AN EXTENT WHERE THE PARKING BRAKE CAN BECOME INEFFECTIVE IN IMMOBILIZING A PARKED VEHICLE.GM'S ACTION COVERS AN ESTIMATED TOTAL OF 142,585 VEHICLES.DEALERS WILL INSTALL A LOW-FORCE SPRING CLIP RETAINER FOR VEHICLES EQUIPPED WITH THE PBR PARKING BRAKE SYSTEM AND INSTALL A REDESIGNED PARKING BRAKE CABLE ASSEMBLY ON VEHICLES EQUIPPED WITH THE TRW PARKING BRAKE SYSTEM. A TOTAL OF 58 NON-DUPLICATIVE COMPLAINTS WERE RECEIVED BY ODI AND GM CONCERNING THE APPROXIMATELY 59,000 MY 1999-2002 C/K 1500 SERIES PICKUP TRUCKS WITH THE PBR PARKING BRAKE SYSTEM.THESE INCLUDED 22 ALLEGED ROLLAWAY INCIDENTS, RESULTING IN A RATE OF 38.5 ROLLAWAY INCIDENTS PER 100,000 VEHICLES.ODI IS AWARE OF 24 COMPLAINTS REGARDING THE MY 2001-2005 C/K 2500 AND 3500 SERIES MANUAL TRANSMISSION TRUCKS RECALLED BY GM, INCLUDING 5 ALLEGING ROLLAWAY INCIDENTS.THOUGH THE CONDITIONS DESCRIBED IN GM'S LETTER ARE ALSO PRESENT IN THE C/K TRUCKS WITH AUTOMATIC TRANSMISSIONS, THE ROLLAWAY RATE IN THOSE VEHICLES WAS SIMILAR TO THOSE OBSERVED IN PEER VEHICLES STUDIED BY ODI IN THIS INVESTIGATION.THIS ENGINEERING ANALYSIS IS CLOSED. FOR ADDITIONAL INFORMATION, SEE THE ATTACHED CLOSING REPORT.
Parking Brake:conventional:mechanical:linkage And Cable
IN A LETTER DATED APRIL 20, 2005, GM NOTIFIED NHTSA THAT IT HAD DECIDED THAT DEFECTS THAT RELATE TO MOTOR VEHICLE SAFETY EXIST IN CERTAIN MODEL YEAR (MY) 1999-2002 C/K 1500 SERIES (PBR PARKING BRAKE SYSTEM) AND MY 2001-2005 C/K 2500 AND 3500 SERIES (TRW PARKING BRAKE SYSTEM) PICKUPS WITH MANUAL TRANSMISSIONS.ACCORDING TO GM, SOME OF THESE VEHICLES MAY HAVE CONDITIONS THAT CAUSE THE FRICTION LININGS TO WEAR TO AN EXTENT WHERE THE PARKING BRAKE CAN BECOME INEFFECTIVE IN IMMOBILIZING A PARKED VEHICLE.GM'S ACTION COVERS AN ESTIMATED TOTAL OF 142,585 VEHICLES.DEALERS WILL INSTALL A LOW-FORCE SPRING CLIP RETAINER FOR VEHICLES EQUIPPED WITH THE PBR PARKING BRAKE SYSTEM AND INSTALL A REDESIGNED PARKING BRAKE CABLE ASSEMBLY ON VEHICLES EQUIPPED WITH THE TRW PARKING BRAKE SYSTEM. A TOTAL OF 58 NON-DUPLICATIVE COMPLAINTS WERE RECEIVED BY ODI AND GM CONCERNING THE APPROXIMATELY 59,000 MY 1999-2002 C/K 1500 SERIES PICKUP TRUCKS WITH THE PBR PARKING BRAKE SYSTEM.THESE INCLUDED 22 ALLEGED ROLLAWAY INCIDENTS, RESULTING IN A RATE OF 38.5 ROLLAWAY INCIDENTS PER 100,000 VEHICLES.ODI IS AWARE OF 24 COMPLAINTS REGARDING THE MY 2001-2005 C/K 2500 AND 3500 SERIES MANUAL TRANSMISSION TRUCKS RECALLED BY GM, INCLUDING 5 ALLEGING ROLLAWAY INCIDENTS.THOUGH THE CONDITIONS DESCRIBED IN GM'S LETTER ARE ALSO PRESENT IN THE C/K TRUCKS WITH AUTOMATIC TRANSMISSIONS, THE ROLLAWAY RATE IN THOSE VEHICLES WAS SIMILAR TO THOSE OBSERVED IN PEER VEHICLES STUDIED BY ODI IN THIS INVESTIGATION.THIS ENGINEERING ANALYSIS IS CLOSED. FOR ADDITIONAL INFORMATION, SEE THE ATTACHED CLOSING REPORT.
Parking Brake
IN A LETTER DATED APRIL 20, 2005, GM NOTIFIED NHTSA THAT IT HAD DECIDED THAT DEFECTS THAT RELATE TO MOTOR VEHICLE SAFETY EXIST IN CERTAIN MODEL YEAR (MY) 1999-2002 C/K 1500 SERIES (PBR PARKING BRAKE SYSTEM) AND MY 2001-2005 C/K 2500 AND 3500 SERIES (TRW PARKING BRAKE SYSTEM) PICKUPS WITH MANUAL TRANSMISSIONS.ACCORDING TO GM, SOME OF THESE VEHICLES MAY HAVE CONDITIONS THAT CAUSE THE FRICTION LININGS TO WEAR TO AN EXTENT WHERE THE PARKING BRAKE CAN BECOME INEFFECTIVE IN IMMOBILIZING A PARKED VEHICLE.GM'S ACTION COVERS AN ESTIMATED TOTAL OF 142,585 VEHICLES.DEALERS WILL INSTALL A LOW-FORCE SPRING CLIP RETAINER FOR VEHICLES EQUIPPED WITH THE PBR PARKING BRAKE SYSTEM AND INSTALL A REDESIGNED PARKING BRAKE CABLE ASSEMBLY ON VEHICLES EQUIPPED WITH THE TRW PARKING BRAKE SYSTEM. A TOTAL OF 58 NON-DUPLICATIVE COMPLAINTS WERE RECEIVED BY ODI AND GM CONCERNING THE APPROXIMATELY 59,000 MY 1999-2002 C/K 1500 SERIES PICKUP TRUCKS WITH THE PBR PARKING BRAKE SYSTEM.THESE INCLUDED 22 ALLEGED ROLLAWAY INCIDENTS, RESULTING IN A RATE OF 38.5 ROLLAWAY INCIDENTS PER 100,000 VEHICLES.ODI IS AWARE OF 24 COMPLAINTS REGARDING THE MY 2001-2005 C/K 2500 AND 3500 SERIES MANUAL TRANSMISSION TRUCKS RECALLED BY GM, INCLUDING 5 ALLEGING ROLLAWAY INCIDENTS.THOUGH THE CONDITIONS DESCRIBED IN GM'S LETTER ARE ALSO PRESENT IN THE C/K TRUCKS WITH AUTOMATIC TRANSMISSIONS, THE ROLLAWAY RATE IN THOSE VEHICLES WAS SIMILAR TO THOSE OBSERVED IN PEER VEHICLES STUDIED BY ODI IN THIS INVESTIGATION.THIS ENGINEERING ANALYSIS IS CLOSED. FOR ADDITIONAL INFORMATION, SEE THE ATTACHED CLOSING REPORT.
PE03057 · Parking Brake Failure
Opened Dec 8, 2003 · Closed Apr 9, 2004
Status: closed (inferred from source dates) · Parking Brake
ODI OPENED PE03-057 TO ASSESS PARKING BRAKE INEFFECTIVENESS IN THE SUBJECT VEHICLES.THESE VEHICLES ARE EQUIPPED WITH FOUR WHEEL DISC BRAKES THAT INCORPORATE A SINGLE-SHOE DRUM-IN-HAT PARKING BRAKE INDEPENDENT OF THE SERVICE BRAKES.COMPLAINT AND WARRANTY DATA INDICATE THAT THE PARKING BRAKE LININGS TEND TO WEAR OUT EARLY IN THE LIFE OF THE VEHICLE (AT AN AVERAGE OF 24 MONTHS IN SERVICE), REDUCING THE PARKING BRAKE SYSTEM'S TORQUE BELOW THAT NEEDED TO IMMOBILIZE THE VEHICLE.GM HAS ATTRIBUTED THIS ACCELERATED WEAR TO FOREIGN MATERIAL INTRUSION AND A FAILURE OF THE BRAKE SHOE TO PROPERLY SELF-CENTER WITHIN ITS BRAKE DRUM.EFFECTIVE WITH THE START OF MY 2003 PRODUCTION, A NEWER REDUCED FORCE HOLD-DOWN CLIP WAS INTRODUCED TO FACILITATE BRAKE SHOE DISENGAGEMENT FROM THE DRUM SURFACE.THIS PART IS ALSO AVAILABLE AT THE SERVICE LEVEL FOR THE MY 1999-2002 VEHICLES.GM HAS INDICATED THAT THE PAKING BRAKE IS INTENDED TO OPERATE IN CONJUNCTION WITH THE TRANSMISSION TO IMMOBILZE PARKED VEHICLES, AND THAT IN MANY CASES, ACCELERATED PARKING BRAKE LINING WEAR IS CAUSED BY ROUGH USE, VEHICLE MODIFICATIONS, AND DRIVING WITH THE PARKING ENGAGED. ODI HAS UPGRADED THE PRELIMINARY EVALUATION TO AN ENGINEERING ANALYSIS TO GATHER FURTHER INFORMATION CONCERNING PARKING BRAKE USAGE FACTORS AND THE CIRCUMSTANCES SURROUNDING THE SEVENTEEN REPORTED VEHICLE CRASHES.
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