IllustrationCOASTING 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
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.
About this comparison →How this year compares
Owner complaints by model year
Compare all Silverado 1500 years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
560–25K
11025–50K
15450–75K
15275–100K
175100–150K
79150K+
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
What owners actually said
805 reportsI 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
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.
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
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
I WAS DRIVING HOME AFTER MORITZ CHEVROLET IN FORT WORTH, TEXAS REPLACED A PASSENGERS DOOR MODULE. WHILE DRIVING 5-10 MPH, THE STEERING WHEEL LOCKED DURING LEFT AND RIGHT TURNS AND THE ENGINE SHUT DOWN. AFTER I RESTARTED THE TRUCK, THE STEERING WHEEL WENT BACK TO NORMAL. I ALMOST HIT A CURB AFTER MAKING A RIGHT TURN. I'M AFRAID T…
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I WAS DRIVING HOME AFTER MORITZ CHEVROLET IN FORT WORTH, TEXAS REPLACED A PASSENGERS DOOR MODULE. WHILE DRIVING 5-10 MPH, THE STEERING WHEEL LOCKED DURING LEFT AND RIGHT TURNS AND THE ENGINE SHUT DOWN. AFTER I RESTARTED THE TRUCK, THE STEERING WHEEL WENT BACK TO NORMAL. I ALMOST HIT A CURB AFTER MAKING A RIGHT TURN. I'M AFRAID TO DRIVE MY TRUCK, BECAUSE I COULD HAVE BEEN IN AN ACCIDENT IF I WERE GOING ANY FASTER. *TR
MY SON WAS DRIVING MY TRUCK TO COLLEGE AND PULLED INTO THE PARKING GARAGE AND WHEN LOOKING FOR A SPACE TO PARK THE BRAKE PEDAL WENT ALL THE WAY TO THE FLOOR. HE WAS ABLE TO KEEP GOING LONG ENOUGH FOR THE VEHICLE TO COAST INTO A PARKING SPOT BUT THE BRAKES WERE COMPLETELY OUT. G.M. STATES THAT THE SALT THAT THEY TREAT THE ROADS…
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MY SON WAS DRIVING MY TRUCK TO COLLEGE AND PULLED INTO THE PARKING GARAGE AND WHEN LOOKING FOR A SPACE TO PARK THE BRAKE PEDAL WENT ALL THE WAY TO THE FLOOR. HE WAS ABLE TO KEEP GOING LONG ENOUGH FOR THE VEHICLE TO COAST INTO A PARKING SPOT BUT THE BRAKES WERE COMPLETELY OUT. G.M. STATES THAT THE SALT THAT THEY TREAT THE ROADS WITH ALONG WITH THE WEATHER CAUSED THE LINES TO RUST OUT. IF THAT WAS THE CASE THAT WOULD BE HAPPENING TO ALOT MORE VEHICLES. I THINK THERE IS DEFINITELY A PROBLEM WITH THE BRAKE LINES THAT WERE INSTALLED ON THESE VEHICLES. *TR
I WAS TOWING A NEW RANGER BASS BOAT HOME FROM FISHING. I WAS COMING DOWN HILL TOWARD A STOP SIGN AT A INTERSECTION AND WHEN I HIT THE BRAKES. THE CHECK BRAKES CAME UP ON INFO CENTER. THE PEDAL WENT TO THE FLOOR. I HAD TO JAM IT DOWN IN TO FIRST GEAR AND USE PARKING BREAK TO GET IT SLOWED ENOUGH TO TURN. IT WAS ALSO A 55MPH SPEED…
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I WAS TOWING A NEW RANGER BASS BOAT HOME FROM FISHING. I WAS COMING DOWN HILL TOWARD A STOP SIGN AT A INTERSECTION AND WHEN I HIT THE BRAKES. THE CHECK BRAKES CAME UP ON INFO CENTER. THE PEDAL WENT TO THE FLOOR. I HAD TO JAM IT DOWN IN TO FIRST GEAR AND USE PARKING BREAK TO GET IT SLOWED ENOUGH TO TURN. IT WAS ALSO A 55MPH SPEED LIMIT ROAD. THANK GOD NO ONE WAS COMING. I GOT PULLED OFF THE ROAD AND CHECKED WHAT WAS GOING ON. THE HARD BREAK LINE GOING TO THE DRIVER SIDE REAR WAS BLOWN APART. IT HAD RUSTED COMPLETELY IN HALF. AFTER FURTHER INVESTIGATION OF THE LINES THEY ARE ALL IN EXTREMELY BAD SHAPE. THEY ARE ALL RUSTED AND NOW STARTING TO LEAK IN PLACES. ALONG WITH THAT MY GAS LINE IS NOW RUSTED IN HALF AND NOW LEAKING. SOMETHING NEEDS TO BE DONE BEFORE SOMEONE IS KILLED. *TR
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.
2003 CHEVROLET SILVERADO 4X4 PICKUP. SERVICE BRAKE SYSTEM WARNING APPEARED ON DASH DISPLAY. BRAKES ALMOST WENT TO THE FLOOR. CHECKED THE UNDERCARRIAGE AND FOUND A MAJOR BRAKE FLUID LEAK FROM THE REAR DRIVER SIDE BRAKE LINE. ALSO DISCOVERED THAT ALL OF THE BRAKE LINES WERE RUSTED AND CORRODED. AN ONLINE WEB SEARCH REVEALED TOO M…
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2003 CHEVROLET SILVERADO 4X4 PICKUP. SERVICE BRAKE SYSTEM WARNING APPEARED ON DASH DISPLAY. BRAKES ALMOST WENT TO THE FLOOR. CHECKED THE UNDERCARRIAGE AND FOUND A MAJOR BRAKE FLUID LEAK FROM THE REAR DRIVER SIDE BRAKE LINE. ALSO DISCOVERED THAT ALL OF THE BRAKE LINES WERE RUSTED AND CORRODED. AN ONLINE WEB SEARCH REVEALED TOO MANY INCIDENTS REGARDING THE SAME TOPIC. ANY MALFUNCTION OF A VEHICLES BRAKING SYSTEM IS A MAJOR DEFECT AND THERE SHOULD BE A RECALL. *TR
Official recalls
0No recalls in this snapshot.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
3EA11001 · Brake Line Corrosion Failure
Opened Jan 5, 2011 · Closed Apr 8, 2015
Status: closed (inferred from source dates) · Service Brakes, Hydraulic; Service Brakes, Hydraulic:foundation Components:hoses, Lines/piping, And Fittings
On January 11, 2011, ODI opened EA11-001 to investigate allegations of premature brake line corrosion failure in model year (MY) 1999 through 2003 General Motors (GM) full-size pickup trucks and sport utility vehicles sold or registered in the following region of the United States that NHTSA has viewed as salt states for investigations of corrosion related issues:Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia and Wisconsin.The subject vehicles represent the first five MY's of GM's GMT800 platform production, of which approximately 2,038,504 vehicles were sold in salt states (the subject vehicles).The GMT800 platform includes the following vehicles:1999-2007 Chevrolet Silverado and GMC Sierra 1500, 2500 and 3500 series pick-up trucks; 2000-2006 Chevrolet Suburban, Chevrolet Tahoe and GMC Yukon sport utility vehicles; and 2002-2006 Cadillac Escalade and Chevrolet Avalanche sport-utility vehicles.General Motors produced a total of approximately 10,427,062 GMT800 vehicles for sales in the United States, including almost 5 million that were sold in salt states.Although there are over 60 different brake pipe routing configuration used in GMT800 vehicles, with the exception of the rear crossover pipes in MY 200x-2007 vehicles that changed from rear disc to drum brakes, all of the vehicles use brake pipes from the same supplier with a common double-wall, brazed steel pipe design with a combination of hot dip Zinc-Aluminum corrosion protection coating and Aluminum paint outer layer known in the industry as AlGal (ASTM-B750). ODI analysis of field data regarding GMT800 vehicles identified a total of 3,645 complaints of brake pipe corrosion failures, including 107 alleging crashes, and 40 injuries.Though only 20% of total GMT800 production, due to age and region the subject vehicles account for a disproportionate share of the failure experience; with 2,702 of the complaints (75%), 88 of the crashes (82%) and 20 of the injuries (50%) reported in those vehicles.Analysis of the complaints showed strong correlations to vehicle age and region.For vehicles with less than 8 years of service, the complaint rates were minimal for all regions.In the salt states the failure rates begin to climb as the vehicles advance in age, particularly in the Northeast corner of the United States.The complaint rates in the salt states go from less than 0.1 incident per thousand vehicles (IPTV) at 7 years in service to over 1.0 IPTV after the 12th year of service for the subject pickup trucks and utility vehicles.Most of the failures reported to ODI occurred in vehicles with more than 10 years in service.ODI?s investigation did not identify any specific defect conditions that were causing or contributing to the brake pipe failures.Nor did the analysis isolate the problem to any subject vehicle sub-populations when analyzed by vehicle type or production range.The investigation found that vehicles experiencing brake pipe corrosion failures were likely to have general patterns of excessive corrosion on the majority of the brake pipe assembly and appear to be occurring due to expected wear out for the brake pipe coating material used in the subject vehicles and the environmental conditions in severe corrosion states.A safety-related defect has not been identified at this time.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor t
Additional source detail variants (2)
Service Brakes, Hydraulic:foundation Components:hoses, Lines/piping, And Fittings
On January 11, 2011, ODI opened EA11-001 to investigate allegations of premature brake line corrosion failure in model year (MY) 1999 through 2003 General Motors (GM) full-size pickup trucks and sport utility vehicles sold or registered in the following region of the United States that NHTSA has viewed as salt states for investigations of corrosion related issues:Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia and Wisconsin.The subject vehicles represent the first five MY's of GM's GMT800 platform production, of which approximately 2,038,504 vehicles were sold in salt states (the subject vehicles).The GMT800 platform includes the following vehicles:1999-2007 Chevrolet Silverado and GMC Sierra 1500, 2500 and 3500 series pick-up trucks; 2000-2006 Chevrolet Suburban, Chevrolet Tahoe and GMC Yukon sport utility vehicles; and 2002-2006 Cadillac Escalade and Chevrolet Avalanche sport-utility vehicles.General Motors produced a total of approximately 10,427,062 GMT800 vehicles for sales in the United States, including almost 5 million that were sold in salt states.Although there are over 60 different brake pipe routing configuration used in GMT800 vehicles, with the exception of the rear crossover pipes in MY 200x-2007 vehicles that changed from rear disc to drum brakes, all of the vehicles use brake pipes from the same supplier with a common double-wall, brazed steel pipe design with a combination of hot dip Zinc-Aluminum corrosion protection coating and Aluminum paint outer layer known in the industry as AlGal (ASTM-B750). ODI analysis of field data regarding GMT800 vehicles identified a total of 3,645 complaints of brake pipe corrosion failures, including 107 alleging crashes, and 40 injuries.Though only 20% of total GMT800 production, due to age and region the subject vehicles account for a disproportionate share of the failure experience; with 2,702 of the complaints (75%), 88 of the crashes (82%) and 20 of the injuries (50%) reported in those vehicles.Analysis of the complaints showed strong correlations to vehicle age and region.For vehicles with less than 8 years of service, the complaint rates were minimal for all regions.In the salt states the failure rates begin to climb as the vehicles advance in age, particularly in the Northeast corner of the United States.The complaint rates in the salt states go from less than 0.1 incident per thousand vehicles (IPTV) at 7 years in service to over 1.0 IPTV after the 12th year of service for the subject pickup trucks and utility vehicles.Most of the failures reported to ODI occurred in vehicles with more than 10 years in service.ODI?s investigation did not identify any specific defect conditions that were causing or contributing to the brake pipe failures.Nor did the analysis isolate the problem to any subject vehicle sub-populations when analyzed by vehicle type or production range.The investigation found that vehicles experiencing brake pipe corrosion failures were likely to have general patterns of excessive corrosion on the majority of the brake pipe assembly and appear to be occurring due to expected wear out for the brake pipe coating material used in the subject vehicles and the environmental conditions in severe corrosion states.A safety-related defect has not been identified at this time.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor t
Service Brakes, Hydraulic
On January 11, 2011, ODI opened EA11-001 to investigate allegations of premature brake line corrosion failure in model year (MY) 1999 through 2003 General Motors (GM) full-size pickup trucks and sport utility vehicles sold or registered in the following region of the United States that NHTSA has viewed as salt states for investigations of corrosion related issues:Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia and Wisconsin.The subject vehicles represent the first five MY's of GM's GMT800 platform production, of which approximately 2,038,504 vehicles were sold in salt states (the subject vehicles).The GMT800 platform includes the following vehicles:1999-2007 Chevrolet Silverado and GMC Sierra 1500, 2500 and 3500 series pick-up trucks; 2000-2006 Chevrolet Suburban, Chevrolet Tahoe and GMC Yukon sport utility vehicles; and 2002-2006 Cadillac Escalade and Chevrolet Avalanche sport-utility vehicles.General Motors produced a total of approximately 10,427,062 GMT800 vehicles for sales in the United States, including almost 5 million that were sold in salt states.Although there are over 60 different brake pipe routing configuration used in GMT800 vehicles, with the exception of the rear crossover pipes in MY 200x-2007 vehicles that changed from rear disc to drum brakes, all of the vehicles use brake pipes from the same supplier with a common double-wall, brazed steel pipe design with a combination of hot dip Zinc-Aluminum corrosion protection coating and Aluminum paint outer layer known in the industry as AlGal (ASTM-B750). ODI analysis of field data regarding GMT800 vehicles identified a total of 3,645 complaints of brake pipe corrosion failures, including 107 alleging crashes, and 40 injuries.Though only 20% of total GMT800 production, due to age and region the subject vehicles account for a disproportionate share of the failure experience; with 2,702 of the complaints (75%), 88 of the crashes (82%) and 20 of the injuries (50%) reported in those vehicles.Analysis of the complaints showed strong correlations to vehicle age and region.For vehicles with less than 8 years of service, the complaint rates were minimal for all regions.In the salt states the failure rates begin to climb as the vehicles advance in age, particularly in the Northeast corner of the United States.The complaint rates in the salt states go from less than 0.1 incident per thousand vehicles (IPTV) at 7 years in service to over 1.0 IPTV after the 12th year of service for the subject pickup trucks and utility vehicles.Most of the failures reported to ODI occurred in vehicles with more than 10 years in service.ODI?s investigation did not identify any specific defect conditions that were causing or contributing to the brake pipe failures.Nor did the analysis isolate the problem to any subject vehicle sub-populations when analyzed by vehicle type or production range.The investigation found that vehicles experiencing brake pipe corrosion failures were likely to have general patterns of excessive corrosion on the majority of the brake pipe assembly and appear to be occurring due to expected wear out for the brake pipe coating material used in the subject vehicles and the environmental conditions in severe corrosion states.A safety-related defect has not been identified at this time.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor t
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.