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2002 Chevrolet Silverado 2500

Owner reports · Recalls · Investigations

More warning signs than most Silverado 2500 years

Owner complaints for the 2002 Chevrolet Silverado 2500 are substantially higher than the model-year median of 81.

About this comparison →

When problems were reported

Mileage at the reported incident

307 reports with mileage · 44 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, Hydraulic. Review the 117 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes. Review the 88 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine And Engine Cooling. Review the 43 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

21 crash reports6 fire reports7 injury reports

Service Brakes, Hydraulic complaints

117 reports
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66,000 miles · Oct 6, 2011
Service Brakes, Hydraulic

TRUCK ONLY HAS 66K AND BRAKE LINES RUSTED THROUGH. SEEMS TO BE A PROBLEM ON THIS YEAR AND MODEL WITH NO RECALL AS OF YET. EXTREMELY COSTLY TO REPAIR! WOULD LIKE TO SEE A STUDY DONE OF OTHERS WITH THIS PROBLEM. *TR

NHTSA ODI #10428951

91,000 miles · Oct 5, 2011
Service Brakes, Hydraulic

TL* THE CONTACT OWNS A 2006 CHEVROLET SILVERADO 2500. THE CONTACT STATED THAT ALL THE BRAKE LINES WERE RUSTED AND CORRODED. WHILE DRIVING 15 MPH AND DEPRESSING THE BRAKES, THEY WENT ALL THE WAY TO THE FLOORBOARD. A MECHANIC INSPECTED THE BRAKES WHO ADVISED THAT THE BRAKE LINES WOULD NEED REPLACING. THE BRAKE LINES WERE NOT REP…

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TL* THE CONTACT OWNS A 2006 CHEVROLET SILVERADO 2500. THE CONTACT STATED THAT ALL THE BRAKE LINES WERE RUSTED AND CORRODED. WHILE DRIVING 15 MPH AND DEPRESSING THE BRAKES, THEY WENT ALL THE WAY TO THE FLOORBOARD. A MECHANIC INSPECTED THE BRAKES WHO ADVISED THAT THE BRAKE LINES WOULD NEED REPLACING. THE BRAKE LINES WERE NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 915,000. UPDATED 10/26/11 *BF UPDATED 10/28/11

NHTSA ODI #10428818

110,469 miles · Sep 21, 2011
Service Brakes, HydraulicInjury

LATE ON JULY 30, I HAD A SINGLE VEHICLE ACCIDENT. I WAS DRIVING DOWN THE INTERSTATE / TOLL ROAD ON THE WAY BACK FROM THE AIRPORT. I HAD CRUISE CONTROL SET TO 75MPH. WITH NO WARNING, MY REAR WHEELS LOCKED UP. MY TRUCK SKIDDED INTO A BRIDGE. STATE FARM RECOMMENDED MY VEHICLE BE TAKEN TO PURIFOY CHEVROLET FOR REPAIRS. WHEN I WAS…

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LATE ON JULY 30, I HAD A SINGLE VEHICLE ACCIDENT. I WAS DRIVING DOWN THE INTERSTATE / TOLL ROAD ON THE WAY BACK FROM THE AIRPORT. I HAD CRUISE CONTROL SET TO 75MPH. WITH NO WARNING, MY REAR WHEELS LOCKED UP. MY TRUCK SKIDDED INTO A BRIDGE. STATE FARM RECOMMENDED MY VEHICLE BE TAKEN TO PURIFOY CHEVROLET FOR REPAIRS. WHEN I WAS NOTIFIED BY PURIFOY AND STATE FARM THAT MY VEHICLE WAS REPAIRED, I ASKED THE PURIFOY SHOP MANAGER, MY STATE FARM AGENT, AND MY STATE FARM CLAIMS REPRESENTATIVE IF THE VEHICLE HAD BEEN INSPECTED FOR THE CAUSE OF THE LOCKED-AXLE CONDITION WHICH CAUSED THE CRASH AND INJURED ME. ALL STATED THE VEHICLE HAD BEEN INSPECTED, REPAIRED, AND CERTIFIED SAFE TO DRIVE. I PAID MY DEDUCTIBLE AND DROVE HOME THE VEHICLE AND PARKED IT IN MY GARAGE. WITHIN DAYS, I USED THE VEHICLE AND THE AXLE LOCKED UP AGAIN - BADLY WORSENING MY PHYSICAL INJURIES FROM THE FIRST CRASH AND CAUSING ME TO BE PUT INTO SEVERAL MORE WEEKS OF PHYSICAL THERAPY. I AM STILL UNDER A DOCTOR'S CARE. AND, I AM STILL IN PHYSICAL THERAPY RECOVERING FROM THE INJURIES. MY PHYSICAL THERAPIST HAS NOTED INTO MY MEDICAL RECORDS THAT THE SECOND OCCURRENCE GREATLY PROLONGED MY HEALING BY ADDING ADDITIONAL INJURY TO THAT WHICH PREVIOUSLY OCCURRED FROM THE FIRST CRASH. AFTER THIS SECOND OCCURRENCE, I TOOK MY VEHICLE TO A LOCAL SHOP. THE SHOP MANGER LOCALLY STATED THIS WAS A WELL-KNOWN CONDITION OF CHEVROLET TRUCKS: THE REAR AXLE VENT TUBE WAS MANUFACTURED TOO SMALL; THE TUBE PLUGS; THIS FORCES AXLE GREASE INTO THE EMERGENCY BRAKE HUB; THE EMERGENCY BRAKE BECOMES SATURATED AND SWELLS TO CLOSE PROXIMITY TO THE HUB; WHEN THE BRAKE HEATS UP, IT AUTOMATICALLY APPLIES AND CANNOT BE RELEASED UNTIL THE WHEEL ROLLS SLIGHTLY BACKWARD. THE LOCAL SHOP MANAGER REPLACED BOTH AXLE SEALS, CLEANED AND RESIZED THE VENT, AND INSTALLED NEW EMERGENCY BRAKES. THIS CORRECTED THE LOCKED WHEEL/AXLE CONDITION. *TR

NHTSA ODI #10426667

54,688 miles · Sep 19, 2011
Parking BrakeService Brakes, Hydraulic

COMPLETE LOSS OF FRONT BRAKE SYSTEM WHILE DRIVING. I NOTED A SOFT PEDAL WHILE SITTING AT A TRAFFIC LIGHT AND ON THE NEXT BRAKE APPLY THERE WAS LITTLE OR NO DECELERATION UNTIL THE PEDAL WAS NEAR THE FLOOR. THE REAR WHEELS LOCKED UP MOMENTARILY WHILE SLOWING THE VEHICLE AT THE EXTENT OF PEDAL TRAVEL. AFTER STOPPING THE VEHICL…

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COMPLETE LOSS OF FRONT BRAKE SYSTEM WHILE DRIVING. I NOTED A SOFT PEDAL WHILE SITTING AT A TRAFFIC LIGHT AND ON THE NEXT BRAKE APPLY THERE WAS LITTLE OR NO DECELERATION UNTIL THE PEDAL WAS NEAR THE FLOOR. THE REAR WHEELS LOCKED UP MOMENTARILY WHILE SLOWING THE VEHICLE AT THE EXTENT OF PEDAL TRAVEL. AFTER STOPPING THE VEHICLE, I NOTED A STEADY STREAM OF BRAKE FLUID COMING FROM THE LINE WHEN THE BRAKE WAS APPLIED. THE BRAKE LINE RUNNING TO THE ABS UNIT UNDER THE DRIVER SIDE DOOR HAD A LARGE LEAK IN AN AREA OF HEAVY CORROSION. UPON FURTHER INSPECTION I FOUND THAT MOST OF THE BRAKE LINES HAD HEAVY CORROSION ON THE VEHICLE ALTHOUGH NO OTHER LEAKS WERE NOTED. *KB

NHTSA ODI #10426357

64,000 miles · Sep 9, 2011
Service Brakes, Hydraulic

WHILE PULLING OUT OF PARKING LOT OF INSPECTION STATION ON TO SIDE STREET, ON SLIGHT HILL, I DEPRESSED MY BRAKE PEDAL AND IT WENT ALL THE WAY TO THE FLOOR. THE TRUCK SLOWLY STOPPED EVEN THOUGH I WAS ONLY DOING APPROXIMATLY 5 MPH. WHEN I GOT OUT AND LOOKED UNDER THE TRUCK I SAW BRAKE FLUID COMING FROM UNDER THE DRIVER SIDE OF THE …

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WHILE PULLING OUT OF PARKING LOT OF INSPECTION STATION ON TO SIDE STREET, ON SLIGHT HILL, I DEPRESSED MY BRAKE PEDAL AND IT WENT ALL THE WAY TO THE FLOOR. THE TRUCK SLOWLY STOPPED EVEN THOUGH I WAS ONLY DOING APPROXIMATLY 5 MPH. WHEN I GOT OUT AND LOOKED UNDER THE TRUCK I SAW BRAKE FLUID COMING FROM UNDER THE DRIVER SIDE OF THE TRUCK. THE INSPECTOR HAD TOLD ME THAT THE LINES LOOKED TO BE CORRODED AND I WOULD NEED TO GET THEM REPLACED IN A FEW YEARS. ONCE THE BRAKE FAILURE OCCURED HE CAME AND LOOKED AGAIN AND WAS SHOCKED THAT IT WAS AN INSTANT BRAKING. *TR

NHTSA ODI #10424510

170,000 miles · Sep 9, 2011
Service Brakes, Hydraulic

UPON APPLYING THE BRAKES, THE BRAKE PEDAL "DROPPED" TO THE FLOOR AND ALL BRAKING WAS LOST. DRIVER WAS ABLE TO DOWNSHIFT AND USE THE EMERGENCY BRAKE TO STOP SAFELY. UPON INVESTIGATION OF THE FAILURE, THE STEEL BRAKE LINES LOCATED BELOW THE DRIVERS SEAT, UNDER THE CAB, WERE FOUND TO BE HEAVILY CORRODED AND RUPTURED DUE TO THE CORR…

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UPON APPLYING THE BRAKES, THE BRAKE PEDAL "DROPPED" TO THE FLOOR AND ALL BRAKING WAS LOST. DRIVER WAS ABLE TO DOWNSHIFT AND USE THE EMERGENCY BRAKE TO STOP SAFELY. UPON INVESTIGATION OF THE FAILURE, THE STEEL BRAKE LINES LOCATED BELOW THE DRIVERS SEAT, UNDER THE CAB, WERE FOUND TO BE HEAVILY CORRODED AND RUPTURED DUE TO THE CORROSION CAUSING A COMPLETE LOSS OF BRAKING POWER. *TR

NHTSA ODI #10424473

Mileage unknown · Sep 8, 2011
Fuel System, GasolineService Brakes, HydraulicSteering

ALL BRAKE HYDRAULIC LINES ARE RUSTED, ALL FUEL SUPPLY LINES ARE RUSTED, EXCESSIVE RUST ON FRAME AND OTHER UNDERCARRIAGE COMPONENTS, BRAKE ROTORS, CALIPERS ALL COVERED WITH EXCESSIVE. RUST. THESE DEFECTS HAVE SERIOUS SAFETY IMPLICATIONS, WHICH COULD RESULT IN INJURY OR DEATH TO THE VEHICLE OCCUPANTS OR OTHERS. GM SHOULD BE REQUIR…

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ALL BRAKE HYDRAULIC LINES ARE RUSTED, ALL FUEL SUPPLY LINES ARE RUSTED, EXCESSIVE RUST ON FRAME AND OTHER UNDERCARRIAGE COMPONENTS, BRAKE ROTORS, CALIPERS ALL COVERED WITH EXCESSIVE. RUST. THESE DEFECTS HAVE SERIOUS SAFETY IMPLICATIONS, WHICH COULD RESULT IN INJURY OR DEATH TO THE VEHICLE OCCUPANTS OR OTHERS. GM SHOULD BE REQUIRED TO ISSUE A RECALL ON THESE VEHICLES AND REPLACE ALL MAJOR CORRODED BRAKE COMPONENTS WITH NON CORROSIVE METALS, BRAKE FLUID LINES, FUEL LINES, RUSTED FRAMES AND ANY OTHER COMPONENTS. MANY ACCIDENTS WILL BE OCCURRING BECAUSE OF BRAKING FAILURES AND FRAME FAILURE. THIS RECALL SHOULD BE ISSUED IMMEDIATELY BEFORE ANY OTHER FAILURES OCCUR. THESE GM TRUCKS ALSO HAVE DEFECTIVE STEERING BOXES THAT FEEL LOOSE WHEN ROUNDING CORNERS. I HAVE HAD A 1995, 2001, 2002 CHEVY AND GMC WITH SAME PROBLEM THEY NEVER STOOD BEHIND THIS PROBLEM OTHER THAN TO PUT SOME GREASE IN WHICH WAS A TEMPORARY FIX. *TR

NHTSA ODI #10424289

75,000 miles · Sep 2, 2011
Service Brakes, HydraulicCrash

TL* THE CONTACT OWNS A 2002 CHEVROLET SILVERADO 2500 HD. THE CONTACT WAS DRIVING 25 MPH WHEN THE BRAKES WERE APPLIED AND FAILED. THE FAILURE CAUSED THE CONTACT TO CRASH INTO ANOTHER VEHICLE. THERE WERE NO INJURIES. A POLICE REPORT WAS FILED AND THE VEHICLE WAS TOWED TO THE DEALER. THE DEALER CONFIRMED THAT THE BRAKE LINES WERE C…

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TL* THE CONTACT OWNS A 2002 CHEVROLET SILVERADO 2500 HD. THE CONTACT WAS DRIVING 25 MPH WHEN THE BRAKES WERE APPLIED AND FAILED. THE FAILURE CAUSED THE CONTACT TO CRASH INTO ANOTHER VEHICLE. THERE WERE NO INJURIES. A POLICE REPORT WAS FILED AND THE VEHICLE WAS TOWED TO THE DEALER. THE DEALER CONFIRMED THAT THE BRAKE LINES WERE CORRODED AND NEEDED REPLACEMENT. THE MANUFACTURER WAS NOT CONTACTED, BUT THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS 75,000 AND THE CURRENT MILEAGE WAS 114,000.

NHTSA ODI #10423031

140,000 miles · Aug 18, 2011
Service Brakes, Hydraulic

TL* THE CONTACT OWNS A 2002 CHEVROLET SILVERADO 2500 HD. THE CONTACT STATED THAT WHILE DRIVING AT LOW SPEEDS AND DEPRESSING THE BRAKE PEDAL, THE ANTI-LOCK BRAKING SYSTEM WOULD ACTIVATE. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER, WHO STATED THAT THE WHEELS SPEED SENSOR NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE …

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TL* THE CONTACT OWNS A 2002 CHEVROLET SILVERADO 2500 HD. THE CONTACT STATED THAT WHILE DRIVING AT LOW SPEEDS AND DEPRESSING THE BRAKE PEDAL, THE ANTI-LOCK BRAKING SYSTEM WOULD ACTIVATE. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER, WHO STATED THAT THE WHEELS SPEED SENSOR NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED AND OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 140,000.

NHTSA ODI #10419964

126,000 miles · Aug 14, 2011
Service Brakes, Hydraulic

I WAS MOVING MY 2002 CHEVY SILVERADO 2500 HD FROM ITS NORMAL PARKING SPOT TO HOOK UP TO OUT TOWABLE RV. WHILE ALIGNING TO THE RV SUDDENLY THE BRAKE PEDAL HIT THE FLOOR. I NOTICED 2 MORE BRAKE LINES HAVE RUPTURED. YES 2 MORE, I HAVE ALREADY REPLACED 2 BRAKE LINES. AS OF AUGUST 14 2011 I HAVE WRITTEN AN EMAIL TO CHEVROLET AS MY VE…

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I WAS MOVING MY 2002 CHEVY SILVERADO 2500 HD FROM ITS NORMAL PARKING SPOT TO HOOK UP TO OUT TOWABLE RV. WHILE ALIGNING TO THE RV SUDDENLY THE BRAKE PEDAL HIT THE FLOOR. I NOTICED 2 MORE BRAKE LINES HAVE RUPTURED. YES 2 MORE, I HAVE ALREADY REPLACED 2 BRAKE LINES. AS OF AUGUST 14 2011 I HAVE WRITTEN AN EMAIL TO CHEVROLET AS MY VEHICLE SITS IN THE DRIVEWAY WITH RUPTURED, RUSTED BRAKE LINES. I DO NOT EVEN WANT TO IMAGINE THE CONSEQUENCES OF A RUPTURED BRAKE LINE WHILE EMPTY OR TOWING OUR RV AT NORMAL DRIVING SPEEDS. I TRULY FEEL MY FAMILY'S LIFE IS AT RISK IN THIS VEHICLE. FURTHERMORE I CAN SPECULATE THAT THE RESALE VALUE HAS BEEN EFFECTED. MORALLY I COULD NOT SELL THIS VEHICLE KNOWING THERE IS A MAJOR SAFETY ISSUE LOOMING. *TR

NHTSA ODI #10419414

Official recalls

1

01V220000 · Interior Lighting

Jun 26, 2001

VEHICLE DESCRIPTION: CERTAIN PICKUP TRUCKS EQUIPPED WITH 6.6L DIESEL ENGINES FAIL TO COMPLY WITH REQUIREMENTS OF FMVSS NO. 105, "HYDRAULIC AND ELECTRIC BRAKE SYSTEMS." THESE VEHICLES HAVE A BRAKE SYSTEM WARNING LIGHT IN THE INSTRUMENT CLUSTER THAT MAY NOT ILLUMINATE WHEN THE BRAKE FLUID IS LOW. IN ADDITION, WHEN THE BRAKE FLUID IS LOW, THE VEHICLE MAY NOT MEET THE PARTIAL SYSTEM REQUIREMENTS OF FMVSS NO. 105.

Consequence & remedy

Consequence: THESE CONDITIONS COULD RESULT IN REDUCED BRAKING CAPABILITY, WHICH COULD LEAD TO A CRASH.

Remedy: DEALERS WILL CHANGE THE LOCATION OF A WIRE CONNECTION IN THE UNDERHOOD BUSSED ELECTRICAL CENTER. OWNER NOTIFICATION BEGAN JULY 9, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT CHEVROLET AT 1-800-222-1020 OR GMC AT 1-800-462-8782.

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

4

EA07013 · Trailer Hitch Receiver Failure

Opened Sep 14, 2007 · Closed Sep 12, 2008

Status: closed (inferred from source dates) · Trailer Hitches

COMPLAINT REPORTS ALLEGE POOR WELD QUALITY AND/OR BENDING OF THE SUBJECT VEHICLE ORIGINAL EQUIPMENT TRAILER HITCH RECEIVER.THE AGENCY'S INVESTIGATION INCLUDED ANALYSIS OF MANUFACTURER AND AGENCY INCIDENT REPORTS, REVIEW OF POLICE REPORTS, ANALYSIS OF THE AGENCY'S FATAL ANALYSIS REPORTING SYSTEM, A VEHICLE OWNER SURVEY, INSPECTION OF TOW VEHICLES/HITCHES AND ANALYSIS OF FAILED PARTS.INCIDENTS OF WELD FAILURE WERE RARE AND ASSOCIATED WITH VERY LOW-SPEED DRIVING (TURNING, BACKING AND SUDDEN STOPPING).INCIDENTS OF BENDING WERE ASSOCIATED WITH IMPROPER TRAILER HITCH ADJUSTMENT OR OVERLOADING. A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.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 THIS ISSUE AND RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE DOCUMENT SEARCH FILE FOR ADDITION INFORMATION.

PE07025 · Trailer Hitch Receiver Failure

Opened May 14, 2007 · Closed Sep 14, 2007

Status: closed (inferred from source dates) · Trailer Hitches

GM PROVIDED ADDITIONAL DATA REGARDING ALLEGATIONS OF FAILURE OF THE TRAILER HITCH.ODI REVIEWED THAT AS WELL AS OTHER DATA PROVIDED BY PEER MANUFACTURERS.BASED ON OUR REVIEW, ODI FINDS THE NEED TO FURTHER INVESTIGATE THIS ISSUE.THIS PRELIMINARY EVALUATION IS UPGRADED TO AN ENGINEERING ANALYSIS (EA07-013) FOR FURTHER ASSESSMENT AND STUDY OF THIS ISSUE.

EA04012 · Hydraulic Pump Failres

Opened Apr 30, 2004 · Closed Feb 28, 2005

Status: closed (inferred from source dates) · Service Brakes, Hydraulic:power Assist; Steering:hydraulic Power Assist System

GM IS CONDUCTING A RECALL ON ALL SUBJECT VEHICLES BUILD BETWEEN MAY 1999 AND OCTOBER 14, 1999.SIGNIFICANT CHANGES WERE INCORPORATED INTO PRODUCTION IN EARLY OCTOBER 1999, AND VEHICLES BUILT AFTER THAT DATE HAVE LOWER WARRANTY FAILURE RATES.THE COMPLAINT AND WARRANTY DATA APPEAR TO SUPPORT THE EFFECTIVENESS OF THESE CHANGES. GM MADE ADDITIONAL CHANGES IN NOVEMBER 1999, FEBRUARY 2000, MAY 2001, AND FEBRUARY 2004.ODI WILL CONTINUE TO MONITOR THIS PROBLEM AND WILL TAKE FURTHER ACTION, IF WARRANTED, IN THE FUTURE.FOR FURTHER TECHNICAL DETAILS SEE THE ATTACHED ENGINEERING ANALYSIS REPORT.

Additional source detail variants (2)

Service Brakes, Hydraulic:power Assist

GM IS CONDUCTING A RECALL ON ALL SUBJECT VEHICLES BUILD BETWEEN MAY 1999 AND OCTOBER 14, 1999.SIGNIFICANT CHANGES WERE INCORPORATED INTO PRODUCTION IN EARLY OCTOBER 1999, AND VEHICLES BUILT AFTER THAT DATE HAVE LOWER WARRANTY FAILURE RATES.THE COMPLAINT AND WARRANTY DATA APPEAR TO SUPPORT THE EFFECTIVENESS OF THESE CHANGES. GM MADE ADDITIONAL CHANGES IN NOVEMBER 1999, FEBRUARY 2000, MAY 2001, AND FEBRUARY 2004.ODI WILL CONTINUE TO MONITOR THIS PROBLEM AND WILL TAKE FURTHER ACTION, IF WARRANTED, IN THE FUTURE.FOR FURTHER TECHNICAL DETAILS SEE THE ATTACHED ENGINEERING ANALYSIS REPORT.

Steering:hydraulic Power Assist System

GM IS CONDUCTING A RECALL ON ALL SUBJECT VEHICLES BUILD BETWEEN MAY 1999 AND OCTOBER 14, 1999.SIGNIFICANT CHANGES WERE INCORPORATED INTO PRODUCTION IN EARLY OCTOBER 1999, AND VEHICLES BUILT AFTER THAT DATE HAVE LOWER WARRANTY FAILURE RATES.THE COMPLAINT AND WARRANTY DATA APPEAR TO SUPPORT THE EFFECTIVENESS OF THESE CHANGES. GM MADE ADDITIONAL CHANGES IN NOVEMBER 1999, FEBRUARY 2000, MAY 2001, AND FEBRUARY 2004.ODI WILL CONTINUE TO MONITOR THIS PROBLEM AND WILL TAKE FURTHER ACTION, IF WARRANTED, IN THE FUTURE.FOR FURTHER TECHNICAL DETAILS SEE THE ATTACHED ENGINEERING ANALYSIS REPORT.

PE04004 · Hydraulic Pump Shaft Failures

Opened Jan 8, 2004 · Closed Apr 30, 2004

Status: closed (inferred from source dates) · Service Brakes, Hydraulic; Service Brakes, Hydraulic:power Assist; Service Brakes, Hydraulic:power Assist:hydraulic; Steering:hydraulic Power Assist System; Steering:hydraulic Power Assist:pump

THE PRELIMINARY EVAULATION IS BEING UPGRADED.DURING THE EA ODI WILL LIMITITS INVESTIGATION TO ONLY THOSE VEHICLES EQUIPPED WITH A HYDRO-BOOST SYSTEM, WHICH PROVIDES POWER ASSIST TO THE BRAKING AND STEERING SYTEMS.VACCUUM BRAKE BOOSTER VEHICLES ARE EXCLUDED.ODI HASEXPANDED THE SCOPE OF THE EA TO INCLUDE MODEL YEARS2003 AND 2004, ASDURING THE PE, ODI LEARNED THAT THE HYDROBOAST PUMPS WERE MODIFIED IN FEBRAURY 2004.THEREFORE,ODI HAS EXPANDED THE SCOPE TO INCLUDE THE ADDITIONAL MODEL YEARS.ODI'S IS CONCERNED BECAUSE THISISA SUDDEN FAILURE THAT AFFECTS TWO CRITICAL SYSTEMS OF THE VEHICLE, BRAKES AND STEERING, AT THE SAME TIME.THE ABILITY OF THE OPERATOR TO HANDLE THE DUAL FAILURES IS A CONCERN. FURTHER, THESE VEHICLES TEND TO BE WORK VEHICLES, WITH SOME OVER 10,000 POUNDS GVWR AND MANY EQUIPPED TO PULL LARGE TRAILERS.DUAL FAILURES OF HEAVILY LOADED VEHICLES AND VEHICLES PULLING TRAILERS FURTHER INCREASES THE SAFETY RISK.ODI PLANS TO CONDUCT TESTING TO QUANTIFY THE BRAKING AND STEERING PERFORMANCE DEGRADATION AND THE IMPACT ON SAFE VEHICLE CONTROL, WHEN A HYDROBOAST PUMP FAILS.

Additional source detail variants (5)

Service Brakes, Hydraulic

THE PRELIMINARY EVAULATION IS BEING UPGRADED.DURING THE EA ODI WILL LIMITITS INVESTIGATION TO ONLY THOSE VEHICLES EQUIPPED WITH A HYDRO-BOOST SYSTEM, WHICH PROVIDES POWER ASSIST TO THE BRAKING AND STEERING SYTEMS.VACCUUM BRAKE BOOSTER VEHICLES ARE EXCLUDED.ODI HASEXPANDED THE SCOPE OF THE EA TO INCLUDE MODEL YEARS2003 AND 2004, ASDURING THE PE, ODI LEARNED THAT THE HYDROBOAST PUMPS WERE MODIFIED IN FEBRAURY 2004.THEREFORE,ODI HAS EXPANDED THE SCOPE TO INCLUDE THE ADDITIONAL MODEL YEARS.ODI'S IS CONCERNED BECAUSE THISISA SUDDEN FAILURE THAT AFFECTS TWO CRITICAL SYSTEMS OF THE VEHICLE, BRAKES AND STEERING, AT THE SAME TIME.THE ABILITY OF THE OPERATOR TO HANDLE THE DUAL FAILURES IS A CONCERN. FURTHER, THESE VEHICLES TEND TO BE WORK VEHICLES, WITH SOME OVER 10,000 POUNDS GVWR AND MANY EQUIPPED TO PULL LARGE TRAILERS.DUAL FAILURES OF HEAVILY LOADED VEHICLES AND VEHICLES PULLING TRAILERS FURTHER INCREASES THE SAFETY RISK.ODI PLANS TO CONDUCT TESTING TO QUANTIFY THE BRAKING AND STEERING PERFORMANCE DEGRADATION AND THE IMPACT ON SAFE VEHICLE CONTROL, WHEN A HYDROBOAST PUMP FAILS.

Service Brakes, Hydraulic:power Assist

THE PRELIMINARY EVAULATION IS BEING UPGRADED.DURING THE EA ODI WILL LIMITITS INVESTIGATION TO ONLY THOSE VEHICLES EQUIPPED WITH A HYDRO-BOOST SYSTEM, WHICH PROVIDES POWER ASSIST TO THE BRAKING AND STEERING SYTEMS.VACCUUM BRAKE BOOSTER VEHICLES ARE EXCLUDED.ODI HASEXPANDED THE SCOPE OF THE EA TO INCLUDE MODEL YEARS2003 AND 2004, ASDURING THE PE, ODI LEARNED THAT THE HYDROBOAST PUMPS WERE MODIFIED IN FEBRAURY 2004.THEREFORE,ODI HAS EXPANDED THE SCOPE TO INCLUDE THE ADDITIONAL MODEL YEARS.ODI'S IS CONCERNED BECAUSE THISISA SUDDEN FAILURE THAT AFFECTS TWO CRITICAL SYSTEMS OF THE VEHICLE, BRAKES AND STEERING, AT THE SAME TIME.THE ABILITY OF THE OPERATOR TO HANDLE THE DUAL FAILURES IS A CONCERN. FURTHER, THESE VEHICLES TEND TO BE WORK VEHICLES, WITH SOME OVER 10,000 POUNDS GVWR AND MANY EQUIPPED TO PULL LARGE TRAILERS.DUAL FAILURES OF HEAVILY LOADED VEHICLES AND VEHICLES PULLING TRAILERS FURTHER INCREASES THE SAFETY RISK.ODI PLANS TO CONDUCT TESTING TO QUANTIFY THE BRAKING AND STEERING PERFORMANCE DEGRADATION AND THE IMPACT ON SAFE VEHICLE CONTROL, WHEN A HYDROBOAST PUMP FAILS.

Service Brakes, Hydraulic:power Assist:hydraulic

THE PRELIMINARY EVAULATION IS BEING UPGRADED.DURING THE EA ODI WILL LIMITITS INVESTIGATION TO ONLY THOSE VEHICLES EQUIPPED WITH A HYDRO-BOOST SYSTEM, WHICH PROVIDES POWER ASSIST TO THE BRAKING AND STEERING SYTEMS.VACCUUM BRAKE BOOSTER VEHICLES ARE EXCLUDED.ODI HASEXPANDED THE SCOPE OF THE EA TO INCLUDE MODEL YEARS2003 AND 2004, ASDURING THE PE, ODI LEARNED THAT THE HYDROBOAST PUMPS WERE MODIFIED IN FEBRAURY 2004.THEREFORE,ODI HAS EXPANDED THE SCOPE TO INCLUDE THE ADDITIONAL MODEL YEARS.ODI'S IS CONCERNED BECAUSE THISISA SUDDEN FAILURE THAT AFFECTS TWO CRITICAL SYSTEMS OF THE VEHICLE, BRAKES AND STEERING, AT THE SAME TIME.THE ABILITY OF THE OPERATOR TO HANDLE THE DUAL FAILURES IS A CONCERN. FURTHER, THESE VEHICLES TEND TO BE WORK VEHICLES, WITH SOME OVER 10,000 POUNDS GVWR AND MANY EQUIPPED TO PULL LARGE TRAILERS.DUAL FAILURES OF HEAVILY LOADED VEHICLES AND VEHICLES PULLING TRAILERS FURTHER INCREASES THE SAFETY RISK.ODI PLANS TO CONDUCT TESTING TO QUANTIFY THE BRAKING AND STEERING PERFORMANCE DEGRADATION AND THE IMPACT ON SAFE VEHICLE CONTROL, WHEN A HYDROBOAST PUMP FAILS.

Steering:hydraulic Power Assist:pump

THE PRELIMINARY EVAULATION IS BEING UPGRADED.DURING THE EA ODI WILL LIMITITS INVESTIGATION TO ONLY THOSE VEHICLES EQUIPPED WITH A HYDRO-BOOST SYSTEM, WHICH PROVIDES POWER ASSIST TO THE BRAKING AND STEERING SYTEMS.VACCUUM BRAKE BOOSTER VEHICLES ARE EXCLUDED.ODI HASEXPANDED THE SCOPE OF THE EA TO INCLUDE MODEL YEARS2003 AND 2004, ASDURING THE PE, ODI LEARNED THAT THE HYDROBOAST PUMPS WERE MODIFIED IN FEBRAURY 2004.THEREFORE,ODI HAS EXPANDED THE SCOPE TO INCLUDE THE ADDITIONAL MODEL YEARS.ODI'S IS CONCERNED BECAUSE THISISA SUDDEN FAILURE THAT AFFECTS TWO CRITICAL SYSTEMS OF THE VEHICLE, BRAKES AND STEERING, AT THE SAME TIME.THE ABILITY OF THE OPERATOR TO HANDLE THE DUAL FAILURES IS A CONCERN. FURTHER, THESE VEHICLES TEND TO BE WORK VEHICLES, WITH SOME OVER 10,000 POUNDS GVWR AND MANY EQUIPPED TO PULL LARGE TRAILERS.DUAL FAILURES OF HEAVILY LOADED VEHICLES AND VEHICLES PULLING TRAILERS FURTHER INCREASES THE SAFETY RISK.ODI PLANS TO CONDUCT TESTING TO QUANTIFY THE BRAKING AND STEERING PERFORMANCE DEGRADATION AND THE IMPACT ON SAFE VEHICLE CONTROL, WHEN A HYDROBOAST PUMP FAILS.

Steering:hydraulic Power Assist System

THE PRELIMINARY EVAULATION IS BEING UPGRADED.DURING THE EA ODI WILL LIMITITS INVESTIGATION TO ONLY THOSE VEHICLES EQUIPPED WITH A HYDRO-BOOST SYSTEM, WHICH PROVIDES POWER ASSIST TO THE BRAKING AND STEERING SYTEMS.VACCUUM BRAKE BOOSTER VEHICLES ARE EXCLUDED.ODI HASEXPANDED THE SCOPE OF THE EA TO INCLUDE MODEL YEARS2003 AND 2004, ASDURING THE PE, ODI LEARNED THAT THE HYDROBOAST PUMPS WERE MODIFIED IN FEBRAURY 2004.THEREFORE,ODI HAS EXPANDED THE SCOPE TO INCLUDE THE ADDITIONAL MODEL YEARS.ODI'S IS CONCERNED BECAUSE THISISA SUDDEN FAILURE THAT AFFECTS TWO CRITICAL SYSTEMS OF THE VEHICLE, BRAKES AND STEERING, AT THE SAME TIME.THE ABILITY OF THE OPERATOR TO HANDLE THE DUAL FAILURES IS A CONCERN. FURTHER, THESE VEHICLES TEND TO BE WORK VEHICLES, WITH SOME OVER 10,000 POUNDS GVWR AND MANY EQUIPPED TO PULL LARGE TRAILERS.DUAL FAILURES OF HEAVILY LOADED VEHICLES AND VEHICLES PULLING TRAILERS FURTHER INCREASES THE SAFETY RISK.ODI PLANS TO CONDUCT TESTING TO QUANTIFY THE BRAKING AND STEERING PERFORMANCE DEGRADATION AND THE IMPACT ON SAFE VEHICLE CONTROL, WHEN A HYDROBOAST PUMP FAILS.