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2003 Chevrolet Silverado 1500

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2003 Chevrolet Silverado 1500 do not stand out strongly from the model-year median of 525.

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When problems were reported

Mileage at the reported incident

726 reports with mileage · 79 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.

  • Service Brakes. Review the 273 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 195 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes, Hydraulic. Review the 151 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

26 crash reports7 fire reports8 injury reports

Service Brakes complaints

273 reports
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131,000 miles · May 20, 2013
Service Brakes

DRIVING DOWN 2 LANE ROAD AT APPROXIMATELY 40 IN A 45 MPH ZONE. TRAFFIC LIGHT TURNED YELLOW AT THE WORST POSSIBLE MOMENT. DECIDED TO PANIC STOP, PRESSED THE PEDAL HARD, IMMEDIATELY THE PEDAL WENT TO THE FLOOR AND THE BRAKE WARNING CAME ON. TRUCK DID NOT HAVE SUFFICIENT BRAKING TO STOP AND I HAD TO PLOW THROUGH THE INTERSECTION…

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DRIVING DOWN 2 LANE ROAD AT APPROXIMATELY 40 IN A 45 MPH ZONE. TRAFFIC LIGHT TURNED YELLOW AT THE WORST POSSIBLE MOMENT. DECIDED TO PANIC STOP, PRESSED THE PEDAL HARD, IMMEDIATELY THE PEDAL WENT TO THE FLOOR AND THE BRAKE WARNING CAME ON. TRUCK DID NOT HAVE SUFFICIENT BRAKING TO STOP AND I HAD TO PLOW THROUGH THE INTERSECTION, THANK GOD I MADE IT THROUGH SAFELY. FROM THIS POINT UNTIL I REACHED HOME, VERY LITTLE BRAKING WAS POSSIBLE, VERY UNSAFE. UPON INSPECTION, THE REAR LINE HAD BURST, REQUIRING $200 IN REPAIRS. A FEW MONTHS EARLIER THE GAS LINE RUSTED THROUGH ALSO, COSTING ANOTHER $200. *TR

NHTSA ODI #10512816

127,700 miles · Apr 18, 2013
Service Brakes

APPROACHING A 3 WAY STOP INTERSECTION, UPON DEPRESSING THE BRAKE PEDAL IN ORDER TO STOP AT THE INTERSECTION, THE BRAKE PEDAL WENT TO THE FLOOR. NO WARNING LAMPS OF ANY SORT WERE ILLUMINATED PRIOR TO THE BRAKE PEDAL GOING TO THE FLOOR. PUMPING OF THE PEDAL DID NOT PRODUCE ANY RESISTANCE. AFTER COUPLE MINUTES THE "SERVICE BRAKES" …

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APPROACHING A 3 WAY STOP INTERSECTION, UPON DEPRESSING THE BRAKE PEDAL IN ORDER TO STOP AT THE INTERSECTION, THE BRAKE PEDAL WENT TO THE FLOOR. NO WARNING LAMPS OF ANY SORT WERE ILLUMINATED PRIOR TO THE BRAKE PEDAL GOING TO THE FLOOR. PUMPING OF THE PEDAL DID NOT PRODUCE ANY RESISTANCE. AFTER COUPLE MINUTES THE "SERVICE BRAKES" WARNING CAME ON. I WAS ABLE TO BRING THE TRUCK TO A STOP BY SLOWING DOWN. HAD TO HAVE THE TRUCK TOWED TO A FIRESTONE SERVICE CENTER THE TECHNICIAN, THE SERVICE CONSULTANT, AND I ALL OBSERVED THE RUSTED BRAKE LINES, THEY WERE ALL BADLY CORRODED, ONE OF THE LINES HAD DEVELOPED A PIN HOLE LEAD RESULTING IN THE BRAKE FAILURE. I HAVE OWNED MANY VEHICLES FAR OLDER AND WITH FAR MORE MILEAGE AND HAVE NEVER HAD TO REPLACE THE STEEL BRAKE LINES. I BELIEVE THE DESIGN IS FLAWED (THE ROUTING AND PLACEMENT OF LINES AND MODULE) OR THE BRAKE LINE MATERIAL (STEEL, INSTEAD OF STAINLESS STEEL) IS INSUFFICIENT. *TR

NHTSA ODI #10508656

69,974 miles · Mar 28, 2013
Service Brakes

TL* THE CONTACT OWNS A 2003 CHEVROLET SILVERADO C1500. THE CONTACT STATED THAT HE TRIED TO STOP THE VEHICLE AND THE BRAKE WENT ALL THE WAY TO FLOOR. THE VEHICLE WAS TOWED TO A LOCAL MECHANIC WHO INSPECTED THE FAILURE AND STATED THAT THE ENTIRE BRAKE LINE NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIF…

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TL* THE CONTACT OWNS A 2003 CHEVROLET SILVERADO C1500. THE CONTACT STATED THAT HE TRIED TO STOP THE VEHICLE AND THE BRAKE WENT ALL THE WAY TO FLOOR. THE VEHICLE WAS TOWED TO A LOCAL MECHANIC WHO INSPECTED THE FAILURE AND STATED THAT THE ENTIRE BRAKE LINE NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED WHO OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS 69,974. UPDATED 05/10/13*LJ THE CONSUMER STATED THE BRAKE LINES RUSTED CAUSING BRAKE FLUIDS TO LEAK OUT. UPDATED 05/28/2013 *JS

NHTSA ODI #10504793

115,000 miles · Mar 24, 2013
Service Brakes

HAD JUST DRIVEN 30 MILES ON BACKROADS TO MY PARENTS HOUSE TO PICKUP AN ENCLOSED RACE TRAILER (FULLY LOADED) AND WAS BACKING UP TO HOOKUP, HAD GOTTEN OUT TO CHECK LINEUP AND WHEN I GOT BACK IN TO BACKUP FURTHER THE BRAKE PEDAL WENT TO THE FLOOR AND GOT A "SERVICE BRAKE SYSTEM" WARNING ON THE GAUGES. UPON INVESTIGATION I FOUND ONE…

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HAD JUST DRIVEN 30 MILES ON BACKROADS TO MY PARENTS HOUSE TO PICKUP AN ENCLOSED RACE TRAILER (FULLY LOADED) AND WAS BACKING UP TO HOOKUP, HAD GOTTEN OUT TO CHECK LINEUP AND WHEN I GOT BACK IN TO BACKUP FURTHER THE BRAKE PEDAL WENT TO THE FLOOR AND GOT A "SERVICE BRAKE SYSTEM" WARNING ON THE GAUGES. UPON INVESTIGATION I FOUND ONE OF THE FRONT BRAKE LINES THAT RUN ON TOP OF THE FRAME RAIL IN THE ENGINE BAY THAT RUNS ON THE DRIVERS SIDE NEXT TO THE ENGINE HAD BURST AND THE LINES WERE RUSTED. I WOULD HATE TO WONDER WHAT WOULD OF HAPPENED IF THIS HAPPENED WHILE I WAS PULLING TRAILER ON COUNTRY BACKROADS AS I WAS GETTING READY TO DO......GM REALLY NEEDS TO ADDRESS THIS PROBLEM. *TR

NHTSA ODI #10504343

146,000 miles · Mar 24, 2013
Service Brakes

BRAKE LINES COMPLETELY ROTTED BEYOND REPAIR, SO BAD THAT THEY CANNOT BE REMOVED FROM THE ABS UNIT, WHICH SHOULD NOT BE UNDERNEATH THE TRUCK, SO VULNERABLE TO CORROSION FROM SALT. THEY SHOULD HAVE BEEN STAINLESS LINES, OR ROUTED DIFFERENTLY. SAME WITH THE FUEL LINES. I WAS A DIE HARD CHEVY GUY, BUT THIS IS RIDICULOUS. SOOO MA…

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BRAKE LINES COMPLETELY ROTTED BEYOND REPAIR, SO BAD THAT THEY CANNOT BE REMOVED FROM THE ABS UNIT, WHICH SHOULD NOT BE UNDERNEATH THE TRUCK, SO VULNERABLE TO CORROSION FROM SALT. THEY SHOULD HAVE BEEN STAINLESS LINES, OR ROUTED DIFFERENTLY. SAME WITH THE FUEL LINES. I WAS A DIE HARD CHEVY GUY, BUT THIS IS RIDICULOUS. SOOO MANY PEOPLE HAVE ISSUES WITH THIS, GM NEEDS TO STEP UP. I CAN'T WAIT TO SELL THIS TRUCK AND BUY AN ANTIQUE. *TR

NHTSA ODI #10504305

118,000 miles · Mar 23, 2013
Service Brakes

COASTING TO A STOP SIGN. PRESSED BRAKES AND PEDAL WENT TO FLOOR. ENGAGED EMERGENCY BRAKE JUST BEFORE REAR END COLLISION WITH VEHICLE AT STOP. A PUDDLE OF BRAKE FLUID REMAINED AFTER A TOW HOME. *TR

NHTSA ODI #10504245

114,896 miles · Mar 16, 2013
Service Brakes

I WAS DRIVING AROUND 45MPH AND WHEN COMING TO A STOP THE BRAKE PEDAL WENT TO THE FLOOR. I DID NOT HAVE TOTAL LOSS OF BRAKES, HOWEVER, IF THIS WAS AN EMERGENCY BRAKING CONDITION, I WOULD NOT HAVE BEEN ABLE TO STOP SAFELY. THE FRONT RIGHT BRAKE LINE RUSTED AND FLUID CAME OUT. THIS IS AN OBVIOUS ENGINEERING FAILURE. BRAKE LINE…

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I WAS DRIVING AROUND 45MPH AND WHEN COMING TO A STOP THE BRAKE PEDAL WENT TO THE FLOOR. I DID NOT HAVE TOTAL LOSS OF BRAKES, HOWEVER, IF THIS WAS AN EMERGENCY BRAKING CONDITION, I WOULD NOT HAVE BEEN ABLE TO STOP SAFELY. THE FRONT RIGHT BRAKE LINE RUSTED AND FLUID CAME OUT. THIS IS AN OBVIOUS ENGINEERING FAILURE. BRAKE LINES SHOULD NOT BE MADE OUT OF MATERIAL THAT CAN RUST. *TR

NHTSA ODI #10503272

101,000 miles · Mar 11, 2013
Service Brakes

TL* THE CONTACT OWNS A 2003 CHEVROLET SILVERADO 1500. THE CONTACT STATED THAT WHILE DECELERATING AND DESCENDING A HILL AT AN UNKNOWN SPEED, THE BRAKE PEDAL WENT TO THE FLOOR AND STOPPING DISTANCE WAS INCREASED. THE CONTACT TOOK THE VEHICLE TO A LOCAL MECHANIC FOR DIAGNOSTICS. THE MECHANIC STATED ALL OF THE BRAKE LINES HAD EXCESS…

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TL* THE CONTACT OWNS A 2003 CHEVROLET SILVERADO 1500. THE CONTACT STATED THAT WHILE DECELERATING AND DESCENDING A HILL AT AN UNKNOWN SPEED, THE BRAKE PEDAL WENT TO THE FLOOR AND STOPPING DISTANCE WAS INCREASED. THE CONTACT TOOK THE VEHICLE TO A LOCAL MECHANIC FOR DIAGNOSTICS. THE MECHANIC STATED ALL OF THE BRAKE LINES HAD EXCESSIVE RUST AND NEEDED TO BE REPLACED. THE CONTACT DID NOT CALL THE MANUFACTURER. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 101,000.

NHTSA ODI #10502339

92,000 miles · Mar 7, 2013
Service Brakes

2003 CHEVY SILVERADO, PURCHASED NEW WITH 92K MILES ON THE CLOCK NOW. WHILE STARTING OUT FROM MY DRIVEWAY, I STOPPED FOR ONCOMING TRAFFIC AND THE BRAKE PEDAL WENT TO THE FLOOR WITH NO PRESSURE RESISTANCE. I RETURNED TO THE GARAGE AND SAW BRAKE FLUID DRIPPING FROM THE LEFT FRONT. A QUICK EXAMINATION SHOWED THAT A STEEL BRAKE LI…

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2003 CHEVY SILVERADO, PURCHASED NEW WITH 92K MILES ON THE CLOCK NOW. WHILE STARTING OUT FROM MY DRIVEWAY, I STOPPED FOR ONCOMING TRAFFIC AND THE BRAKE PEDAL WENT TO THE FLOOR WITH NO PRESSURE RESISTANCE. I RETURNED TO THE GARAGE AND SAW BRAKE FLUID DRIPPING FROM THE LEFT FRONT. A QUICK EXAMINATION SHOWED THAT A STEEL BRAKE LINE BURST OBVIOUSLY DUE TO MASSIVE RUST. THIS IS A SERIOUS, UNEXPECTED AND A CRITICAL DESIGN FAILURE. THIS TRUCK HAS NEVER SEEN SNOW/SALT AND THE STEEL BRAKE LINES ALONG THE UNDERBODY ARE LIKE-NEW (EVEN THOUGH THIS WOULD BE THE AREA THAT CORROSION WOULD BE EXPECTED!). I AM NO LONGER YOUNG AND HAVE DRIVEN MANY VEHICLES WITH OVER A HUNDRED THOUSAND MILES ON MOST OF THEM. I HAVE NEVER HAD A STEEL BRAKE LINE BURST. TO SEE HUNDREDS OF SIMILAR COMPLAINTS JUST ON THIS DATABASE IS CLEAR EVIDENCE OF A SAFETY ISSUE THAT HAS --- TO DATE --- BEEN IGNORED. IF NOT A RECALL, AT LEAST PROVIDE NOTICE TO OWNERS THAT THERE EXISTS A POTENTIALLY FATAL FLAW IN THE MATERIALS USED IN THE BRAKE SYSTEMS OF THESE VEHICLES. SINCE I'M STILL ON THE ORIGINAL FRONT BRAKE PADS, I THINK IT'S SAFE TO SAY I AM A GENTLE DRIVER AND HAVE NOT ABUSED THE BRAKES. THANKS. *TR

NHTSA ODI #10502007

64,834 miles · Feb 18, 2013
Service Brakes

VEHICLE RESIDES IN "SALT BELT" STATE BUT RARELY DRIVEN IN THE WINTER MONTHS; MAINLY TO LEAVE FOR A 2-MONTH TRIP SOUTH. THANKS TO GOD THAT MY WIFE, OTHERS AND I ESCAPED SERIOUS INJURY. JUST PRIOR TO THIS INCIDENT, VEHICLE WAS AT DEALER FOR REGULAR SERVICE/CHECK. PREVIOUS BRAKE WORK AT 47K MILES IN 02/2010 PADS ON ONE WHEEL COM…

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VEHICLE RESIDES IN "SALT BELT" STATE BUT RARELY DRIVEN IN THE WINTER MONTHS; MAINLY TO LEAVE FOR A 2-MONTH TRIP SOUTH. THANKS TO GOD THAT MY WIFE, OTHERS AND I ESCAPED SERIOUS INJURY. JUST PRIOR TO THIS INCIDENT, VEHICLE WAS AT DEALER FOR REGULAR SERVICE/CHECK. PREVIOUS BRAKE WORK AT 47K MILES IN 02/2010 PADS ON ONE WHEEL COMPLETELY GONE AND PADS ON OTHER WERE WORN TO 1/16? THICK. FRONT PADS AT 85% AT THAT TIME. TECHNICIAN BLAMED ?ROAD SALT?. FILED A COMPLAINT WITH GM BUT ONLY GOT A REMINDER THAT VEHICLE WAS NO LONGER UNDER WARRANTY. CURRENT INCIDENT OCCURRED 01/11/13 APPROX. 11 MI FROM NASHVILLE, TN. WHILE ON THE FREEWAY, TRAFFIC AHEAD BEGAN SLOWING DOWN FAST. I BEGAN APPLYING THE BRAKES AND WHEN I PUSHED DOWN HARDER TO STOP AS TRAFFIC STOPPED, I HEARD A "SOUND" LIKE A LOW THUMP AND THE BRAKE PEDAL WENT STRAIGHT TO THE FLOOR. I MANAGED TO WHIP THE TRUCK AROUND THE BACK OF THE CAR IN FRONT OF ME ONTO THE SHOULDER AND AVOID COLLISION, AND FINALLY CAME TO A STOP. I WAS ABLE TO DETERMINE THAT I HAD SOME BRAKING POWER REMAINING, AND WE SLOWLY CONTINUED IN TO NASHVILLE. LOCATED A DEALER WHO INSPECTED THE BRAKES AND SAID FRONT BRAKES WERE COMPLETELY GONE/BRAKE LINE WAS SHOT. IT WAS FRIDAY AFTERNOON, SO IN ADDITION TO THE $2100 IN REPAIRS, WE INCURRED MEAL AND LODGING EXPENSES FOR 3 DAYS/NIGHTS (APPROX. $600), BEFORE THE REPAIR COULD BE COMPLETED ON MONDAY. AGAIN WAS TOLD THAT BRAKE DETERIORATION WAS DUE TO ROAD SALT. I DISAGREE WITH THIS FIRST, VEHICLE IS RARELY DRIVEN IN THE WINTER AND SECOND, I'VE NEVER HAD A SIMILAR PROBLEM WITH ANY OTHER VEHICLE IN ALL THE YEARS I'VE LIVED IN "SALT BELT" STATES. I BELIEVE THERE IS AN INHERENT DESIGN DEFICIENCY WITH THE BRAKES IN THIS VEHICLE. I HAVE THE PARTS IF NEEDED FOR INSPECTION. I CAN BE REACHED BY PHONE AT # LISTED IN COMPLAINT THRU 03/15/13. AFTER THAT AT PERMANENT HOME ADDRESS (LISTED). *TR

NHTSA ODI #10498504

Official recalls

0

No 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

3

EA11001 · 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.