2005 Chevrolet Silverado 1500

Design flaw - Brake light switch- the end section of the internal spring is placed in a position that allows it to potentially slide down and block the space needed for when the plunger is depressed, jamming up the switches ability to properly function. I have not determined what happened to the switch on my truck, but noticed that this scenario was a possibility and felt obligated to report my opinion.

As I approached an intersection to make a left-hand turn, I stepped on my trucks brake pedal. I experienced a complete loss of braking power, with the trucks brake pedal going straight to the floor, after an instant of a firm, solid pedal. Pumped the pedal to try to regain brake operation to no avail. No hydraulic pressure was present. No warning lights or other indications of brake system failure occurred. Truck was driven home a very short distance using e-brake. Brake fluid was seen dripping from the rear axle area in large amounts. Truck was towed to my local garage which found a burst steel brake line at the junction with the rear hydraulic flex hose. Other brake lines were heavily rusted. Rest of the undercarriage was not similarly rust like the brake lines. The garage stated this was not the first Silverado they saw with this problem. All steel lines were replaced with stainless steel lines, and as a precaution we replaced all brake hoses as well. The bleeder screws on the front disk brake calipers, and on the rear wheel cylinders were also found heavily rusted and frozen, so those components were replaced as well. The shop stated this issue of severe corrosion of brake lines and bleeders is very common on this generation of Silverado’s . They have repaired quite a few like mine after similar brake failures. If you research the issue on-line, there certainly is a problem with these trucks. In my 45 years as a mechanic and practicing mechanical engineer, I have never seen brake system components so severely corroded as the ones removed from my truck. I was lucky I wasn’t towing anything, or was at highway speed when the failure occurred. The next owner may not be that lucky if it happens to them.

The contact owns a 2005 Chevrolet Silverado 1500. The contact stated while driving at various speeds, the vehicle started to leak fuel and the brake line would leak causing the brakes to lose power whenever the brake pedal was depressed. The contact also stated that the fuel tank strap fractured due to rust causing the fuel tank to detach from the vehicle. The contact stated that the rear leaf spring fractured due to rust as well. The contact also stated that the entire sub-frame of the vehicle was rusted causing pieces of metal to fall off from the frame while driving. The brake warning light was illuminated. The vehicle was taken to an independent mechanic to be diagnosed. The contact was informed that the brake lines, fuel lines, the rear leaf shackle, and the fuel tank needed to be replaced. The vehicle was repaired. The manufacturer had not been informed of the failure. The failure mileage was approximately 58,000.

THIS IS 3RD TIME MY BRAKES BLOW A LINE IN 2 YEARS AND THE FIRST 2 TIMES ONE TIME I WAS HOLDING MY BRAKES WHILE BACKING UP A HILL ON MY PROPERTY WITH A TRAILER ATTACHED, THE SECOND COMING TO A STOP SIGN AND THIS LAST TIME GOING DOWN A STEEP HILL COMING TO AN INTERSECTION. I JUST CHANGED THE LINE THAT WAS BROKEN THE FIRST TWO TIMES. I HAD FILED A COMPLAINT WITH YOU LAST YEAR BUT I CANNOT FIND THE INFO. THIS TIME I CHANGED ALL OF THE LINES AS IT SCARED ME BAD THIS TIME AS I LIVE IN THE MOUNTAINS AND DID NOT WISH TO PUSH MY LUCK ANY FURTHER. CHEVROLET WANTED OVER $1,200 TO CHANGE THEM OUT USING THE SAME MATERIALS THAT FAILED IN THE FIRST PLACE. I HAD THEM CHANGED AT NAPA FOR $680 USING COPPER/NICKEL WHICH IS A SUPERIOR PRODUCT. GM'S EXCUSE FOR THE LINES RUSTING OUT WAS THE CUSTOMER DID NOT WASH THE LINES OFF WHEN SALT GOT ON THEM. YOU CANNOT GET TO MOST OF THE LINES TO WASH THEM OFF. THE AMOUNT OF BRAKE LINE FAILURES IS OVERWHELMING AND TO SAY THE LEAST DANGEROUS AS HELL. I AM SENDING SOME PHOTOS OF SOME OF THE LINES AND WILL MAIL PIECES OF THE LINE TO YOU IF IT WILL DO ANY GOOD. PLEASE LET ME KNOW IF I SHOULD SEND THE PIECES OF LINE. THANKS [XXX] PS: IT SEEMS THAT I CAN ONLY SEND ONE PHOTO PLEASE LET ME KNOW HOW TO SEND MORE... ('PARTS OF THIS DOCUMENT HAVE BEEN REDACTED TO PROTECT PERSONALLY IDENTIFIABLE INFORMATION PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).')*JB

HI MY NAME IS [XXX] MY EMAIL IS [XXX]. I'VE HAD MY 2005 CHEVROLET SILVERADO SS TRUCK WITH THE 6.0 ENGINE FOR FIVE YEARS. IN THOSE 5 YEARS I HAVE HAD TO CHANGE THE WHEEL HUB ASSEMBLY'S AND THE FRONT ROTORS 7 TIMES. I'M PRETTY SICK OF THIS RECURRING ISSUE I SEE THAT THERE WAS A RECALL ON THE REGULAR SILVERADOS FOR MY YEAR BUT NOT ON THE 6.0 ENGINE I'M NOT SURE WHAT GIVES BUT I NEED THIS PROBLEM TO BE RECTIFIED. THIS IS A NORMAL EVERYDAY DRIVING VEHICLE TO AND FROM WORK NOTHING SPECTACULAR AND THERE SHOULDN'T BE THAT MUCH WEAR AND TEAR ON THOSE PARTS IN THAT LITTLE BIT OF TIME I'VE OWNED TONS OF OTHER VEHICLES FOR THAT AMOUNT OF TIME AND LONGER AND I'VE NEVER HAD TO CHANGE THAT PART ONCE I'VE HAD TO CHANGE IT 7 TIMES ON THIS VEHICLE I REALLY LOVE MY VEHICLE AND DON'T WANT TO SELL IT SO I'M TRYING TO FIGURE OUT IF THERE IS A PERMANENT FIX FOR IT OR A RECALL. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

WHILE DRIVING APPROX 50MPH ON 2-LANE HIGHWAY A BRAKE LINE BURST UNDER HARD BRAKING (VEHICLE IN FRONT OF ME SUDDENLY SLOWED TO MAKE A TURN OFF THE HIGHWAY) DUE TO RUST. PEDAL WENT ALL THE WAY TO THE FLOOR AND I LOST SIGNIFICANT BRAKING POWER. THIS RESULTED IN A MINOR ACCIDENT WHERE I DENTED THE BUMPER OF THE TRUCK THAT WAS TURNING AND SIGNIFICANTLY BENT THE RIGHT END OF MY FRONT BUMPER. WAS ABLE TO CONTINUE THE TRIP THE LAST 50 MILES TO MY DESTINATION BUT BRAKING DISTANCES WERE CONSIDERABLY LONGER THAN NORMAL. TOOK IT TO A LOCAL MECHANIC WHO SAID ALL THE BRAKE LINES WERE RUSTED AND HAD TO BE REPLACED.