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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

Structure complaints

27 reports
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Mileage unknown · Jul 8, 2022
Structure

The undercarriage or frame of our recent purchase of our 2003 used chevrolet k1500 silverado was discovered recently after purchase to be rusted through and through and chipping off day by day. A private master mechanic has looked the truck over and said that it was not safe to drive. Upon further investigating, the panels that …

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The undercarriage or frame of our recent purchase of our 2003 used chevrolet k1500 silverado was discovered recently after purchase to be rusted through and through and chipping off day by day. A private master mechanic has looked the truck over and said that it was not safe to drive. Upon further investigating, the panels that hold up the roof of the truck underneath the interior panels are rusting through and through to the point of breaking. Dealership we bought it from just shrugged their shoulders and said basically oh well, it was sold as is. under the truck on the frame where the wheels are attached, forgive my descriptions but im no mechanic, looks like they can break off at any minute. we have ony about 3/4 of a front and back bumper we later discovered, and the roof of the truck looks as if it had rusted and messed up beause someone before us put plaster to redo the roof of the truck. im scared to put my mother in law in this truck to go anywhere because if it got into a wreck... it would be devestating for everyone. truck has been in a wreck before. pictures and truck is available for inspection upon request,

NHTSA ODI #11472912

160,000 miles · Jan 21, 2018
Electrical SystemStructureUnknown Or Other

'TAKATA RECALL' MY AIR BAGS WERE FRAMED UNSAFE FROM BEING A VEHICLE FROM A WARM CLIMATE. REPLACEMENT WAS NEEDED TO ENSURE SAFE GUARDS.

NHTSA ODI #11063940

160,212 miles · Oct 30, 2016
Service BrakesStructure

I HAVE A 2003 SILVERADO AND UPON ARRIVING HOME I FELT MY BRAKE PEDDLE GO TO THE FLOOR AND I COULDN'T STOP AND BACKED INTO MY TRAILER, I GOT OUT OF THE TRUCK AND NOTICED A HUGE PUDDLE UNDER MY DRIVER SIDE WHEEL. AFTER INVESTIGATING I FOUND THAT THE STEEL HYDRAULIC LINE HAD RUSTED & BROKE. I AM DISABLED WITH 4 AUTO IMMUNE DISEASES…

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I HAVE A 2003 SILVERADO AND UPON ARRIVING HOME I FELT MY BRAKE PEDDLE GO TO THE FLOOR AND I COULDN'T STOP AND BACKED INTO MY TRAILER, I GOT OUT OF THE TRUCK AND NOTICED A HUGE PUDDLE UNDER MY DRIVER SIDE WHEEL. AFTER INVESTIGATING I FOUND THAT THE STEEL HYDRAULIC LINE HAD RUSTED & BROKE. I AM DISABLED WITH 4 AUTO IMMUNE DISEASES AND CANNOT AFFORD TO PUT IT IN THE SHOP SO I ORDERED THE PART, REPLACED IT AND PROCEEDED TO BLEED THE LINE AND FOUND THAT 3 OTHER STEEL LINES HAD HOLES IN THEM OR HAD RUSTED ALL THE WAY THROUGH. I ALSO HAVE RUST ALL UNDER THE TRUCK. I WILL HAVE TO REPLACE THE TWO FRONT SUPPORT BRACES AS THEY HAVE RUSTED ALL THROUGH. AT $120 EACH. SO FROM FRONT TO BACK ALL THE STEEL LINES HAVE RUSTED. I WAS BLESSED TO HAVE HAD THIS HAPPEN IN MY DRIVE. HAD I DRIVEN ANOTHER MILE OR SO I COULD HAVE BEEN KILLED. I NOW HAVE A FEAR OF DRIVING. BEING DISABLED IT IS TAKING ME SEVERAL DAYS TO REPAIR MY VEHICLE, AND STILL HAVE ONE LINE TO REPLACE. I PURCHASED MY SILVERADO BRAND NEW AND I LIVE IN KENTUCKY SO I DON'T HAVE A GREAT DEAL OF ROAD SALT OR SEA SALT. I HAVE OWNED CHEVROLET PRODUCTS MY HOLE LIFE. PRIOR TO THIS TRUCK I HAD A 1989 SILVERADO PURCHASED NEW AND PRIOR TO THAT I OWNED A 1971 MONTE CARLO HANDED DOWN TO ME AND NONE OF THESE VEHICLE HAD ANY PROBLEMS WITH RUST LIKE THAT. THIS SHOULD NOT BE HAPPENING TO VEHICLE WITH THIS FEW OF YEARS. *TR

NHTSA ODI #10920133

147,000 miles · Sep 16, 2016
Structure

AT 60 TO 75MPH THERE IS A BAD VIBRATION OF THE TRUCK IT GETS SO BAD THE FREEWAY INTERCHANGES ARE SCARY...

NHTSA ODI #10907048

188,000 miles · Aug 7, 2016
Service BrakesStructure

I JUST BOUGHT MY TRUCK ABOUT A MONTH AGO. I WAS UNDER IT CHANGING THE OIL AND I NOTICED AN ALARMING AMOUNT OF RUST ON THE FRAME MEMBERS AND THE BRAKE LINES. SOME OF IT LOOKS SO BAD THAT I AM CONCERNED OF HAVING EITHER FRAME BREAKAGE OR A BRAKE LINE FAILING. I HAVE READ MANY OTHER STORIES OF THE SAME THING HAPPENING TO OTHER TRUC…

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I JUST BOUGHT MY TRUCK ABOUT A MONTH AGO. I WAS UNDER IT CHANGING THE OIL AND I NOTICED AN ALARMING AMOUNT OF RUST ON THE FRAME MEMBERS AND THE BRAKE LINES. SOME OF IT LOOKS SO BAD THAT I AM CONCERNED OF HAVING EITHER FRAME BREAKAGE OR A BRAKE LINE FAILING. I HAVE READ MANY OTHER STORIES OF THE SAME THING HAPPENING TO OTHER TRUCKS. I HAVE NOT HAD A FAILURE YET BUT I BELIEVE IT IS JUST A MATTER OF TIME. AFTER READING ALL OF THE HORROR STORIES FROM OTHER OWNERS ON VARIOUS WEB SITES, I AM TERRIFIED EVERY TIME I DRIVE IT THAT THE BRAKES ARE GOING TO FAIL. I CANNOT AFFORD TO SPEND $3000 TO $4000 TO HAVE THE TRUCK FIXED. ESPECIALLY WHEN I CONSIDER IT A MANUFACTURER DEFECT OF A SAFETY ITEM. PLEASE ISSUE A RECALL FOR THESE PROBLEMS BEFORE PEOPLE ARE INJURED OR KILLED BECAUSE THE FRAME HAS BROKEN OR THE BRAKES HAVE FAILED.

NHTSA ODI #10893880

145,000 miles · May 6, 2015
Service BrakesStructure

BRAKE LINING &FRAME. *TR

NHTSA ODI #10714984

95,000 miles · Mar 3, 2015
Structure

TL*THE CONTACT OWNS A 2003 CHEVROLET SILVERADO 1500. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DISCOVERED THAT THERE WAS SEVERE RUST ON THE FRAME AND REAR SHACKLES. THE INDEPENDENT MECHANIC STATED THAT BOTH THE FRAME AND THE REAR SHACKLES NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER W…

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TL*THE CONTACT OWNS A 2003 CHEVROLET SILVERADO 1500. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DISCOVERED THAT THERE WAS SEVERE RUST ON THE FRAME AND REAR SHACKLES. THE INDEPENDENT MECHANIC STATED THAT BOTH THE FRAME AND THE REAR SHACKLES NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 95,000.

NHTSA ODI #10691929

128,650 miles · Sep 18, 2014
Exterior LightingService BrakesStructureCrash

JUST LEAVING HOME TO GO LOOK AT SOME PARTS FOR A POLE BARN AND LEFT DRIVEWAY WENT TO STOP SIGH , I PROCEEDING TO GO DOWN MITCHELL HILL RD AND ON THE SECOND TURN NO BRAKES , LUCKILY I HAVE SOME EXPERIENCE IN THIS AREA AND INSTANTLY APPLIED MY EMERGENCY BRAKE AND PUT TRUCK INTO LOWER GEAR . THIS WAS ENOUGH TO SLOW ME DOWN SO I DI…

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JUST LEAVING HOME TO GO LOOK AT SOME PARTS FOR A POLE BARN AND LEFT DRIVEWAY WENT TO STOP SIGH , I PROCEEDING TO GO DOWN MITCHELL HILL RD AND ON THE SECOND TURN NO BRAKES , LUCKILY I HAVE SOME EXPERIENCE IN THIS AREA AND INSTANTLY APPLIED MY EMERGENCY BRAKE AND PUT TRUCK INTO LOWER GEAR . THIS WAS ENOUGH TO SLOW ME DOWN SO I DIDN'T GO OVER THE GUARD RAIL BUT DID HIT IT ROUGHLY . I MADE IT TO THE BOTTOM AND COASTED TO A STOP . GOT OUT AND LOOKED UNDER HOOD AND TRUCK TO FIND BRAKE FLUID WAS POURING ON TO THE GROUND. I HAD IT TOWED HOME . UPON FURTHER INSPECTION I LOCATED THE CAUSE OF BRAKE FAILURE WAS DUE TO BRAKE LINES BROKE DUE TO HEAVY RUST ALL OVER THEM .. NOW I DO A LITTLE RESEARCH ONLINE FOR REPLACEMENT PARTS AND FIND OUT THAT THIS IS A SERIOUS ISSUE WITH MANY OWNERS OF CHEVROLET SILVERADO'S . WHY HASN'T THEIR BEEN A RECALL . WHY IS BECAUSE OF THE AMOUNT OF MONEY INVOLVED AND GM DOESN'T WANT TO PAY . SO SOMEONE ELSE WILL BE PAID , BUT NOT THE OWNERS . OR A FATALITY WILL HAVE TO OCCUR FOR SOMEONE TO MAKE A DECISION . THAT'S THE WORLD WE LIVE IN NOW ! SAD BUT TRUE . *TR

NHTSA ODI #10637407

160,000 miles · Jul 30, 2014
StructureTires

ON FRIDAY, JUNE 21, 2014 WHILE ON A FRIENDS PROPERTY IN PLACERVILLE, CA, MY SPARE TIRE FELL OFF THE UNDERSIDE OF THE BED OF MY TRUCK. I'D BOUGHT THE TRUCK NEW IN 2003 AND DON'T RECALL EVER HAVING USED THE TIRE SINCE I BOUGHT IT NEW. I WAS ABLE TO FIND A COUPLE OF THE PARTS THAT SECURED THE SPARE UNDER THE BED OF THE TRUCK. IN ON…

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ON FRIDAY, JUNE 21, 2014 WHILE ON A FRIENDS PROPERTY IN PLACERVILLE, CA, MY SPARE TIRE FELL OFF THE UNDERSIDE OF THE BED OF MY TRUCK. I'D BOUGHT THE TRUCK NEW IN 2003 AND DON'T RECALL EVER HAVING USED THE TIRE SINCE I BOUGHT IT NEW. I WAS ABLE TO FIND A COUPLE OF THE PARTS THAT SECURED THE SPARE UNDER THE BED OF THE TRUCK. IN ONE SENSE, I WAS GLAD IT DIDN'T HAPPEN WHILE ON A FREEWAY DOING 65 MPH. WHAT A CATASTROPHE THAT WOULD HAVE BEEN FOR OTHER DRIVERS BEHIND ME. THE VEHICLE IS NOT USED FOR OFF-ROAD PURPOSES. *TR

NHTSA ODI #10617769

230,000 miles · Jul 10, 2014
Fuel/propulsion SystemStructure

MY SON [XXX] WANTED A 4X4 TRUCK SO THIS GUY [XXX] SAID HIS WAS FOR SALE HE COULD TEST DRIVE IT,WELL THE 4X4 DID NOT WORK ON THE TRUCK THE MINUTE MY SON SHIFTED IT IN TO 4 WHEEL DRIVE THE TIRE ROD AND SOMETHING ELSE,SO MY DAUGHTERS FATHER [XXX] WORKS ON VEHICLES AND SALES THEM TOO. WELL I ASKED [XXX] TO HELP GET MY SONS TRUCK BAC…

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MY SON [XXX] WANTED A 4X4 TRUCK SO THIS GUY [XXX] SAID HIS WAS FOR SALE HE COULD TEST DRIVE IT,WELL THE 4X4 DID NOT WORK ON THE TRUCK THE MINUTE MY SON SHIFTED IT IN TO 4 WHEEL DRIVE THE TIRE ROD AND SOMETHING ELSE,SO MY DAUGHTERS FATHER [XXX] WORKS ON VEHICLES AND SALES THEM TOO. WELL I ASKED [XXX] TO HELP GET MY SONS TRUCK BACK FROM [XXX] AND FIX NICKS TRUCK SO WE COULD HAVE A VEHICLE BECAUSE WE WERE SHARING ONE VEHICLE. NICK WANTED AND [XXX] WANTED FINALLY [XXX] FIXED [XXX] TRUCK AND WHEN WE GOT MY SON TRUCK BACK IT WAS MAKING A NOISE,SO [XXX] SAID HE THINKS ITS THE FUEL PUMP NO BIG DEAL,I SAID OK. HE GAVE ME AND ESTIMATE TO FIX NICKS TRUCK OF 2000.00, WELL SOMEONE AT [XXX]"S WAS RIPPING ME OFF IT WAS ONLY 600.00 R AROUND THAT AMOUNT. WELL ME AND MY HUSBAND WERE GOING THROUGH A BAD DIVORCE HE HAD JUST SIGN OVER THE TITLE AND REGISTRATION TO ME,AND IT WAS LEFT IN GLOVE BOX MY FAULT,BUT HE FORGED THE DOCUMENTS PLUS CASH A 500.00 CHECK THAT I STOPPED PAYMENT ON. I MADE TO POLICE REPORTS PLUS THERE'S 2 911 CALLS WHERE WE R CHASING HIM BUT THE SPEED WAS GETTING OUT OF HAND I TOLD MY SON TO BACK OFF,WE PAID 1500.00 FOR THE TRUCK OUR LIFE IS WORTH MORE. I GOT THE COMPLAINT NUMBERS COPS DID NOTHING. WENT TO DMV HE TRIED TWICE THERE TO SWITCH IT THEY TURNED HIM DOWN,SO HE WENT TO A TITLE COMPANY IN LAFAYETTE,LA ON JOHNSTON STREET AND GOT IT DONE. PLUS I PAID MY INSURANCE FOR SIX MONTHS AHEAD, I REPORTED IT TO PROGRESSIVE THEY WERE MAILING MY REFUND CHECK,HE STOLE THAT AND APPLIED IT BACK I THINK HE R SOMEONE GOT IN A WRECK AND TRIED TO CLAIM A INSURANCE CLAIM. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI #10609625

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.