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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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64,000 miles · Feb 25, 2010
Power TrainService Brakes, HydraulicCrash

2002 CHEVROLET SUBURBAN 2500. IN PARKING LOT, PRESSED BRAKE AND TRUCK LURCHED FORWARD CAUSING DAMAGE TO MY SUBURBAN AND ANOTHER CAR RESULTING IN AN INSURANDE SURDHARGE FOR ACCIDENT OVER $2500. DEALER, MIRAK CHEVROLET OF ARLINGTON MA COULD NOT FIND DEFECT. UPON BRAKING TODAY,I FELT A SURGE FORWARD BUT NO ACCIDENT THIS TIME. P…

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2002 CHEVROLET SUBURBAN 2500. IN PARKING LOT, PRESSED BRAKE AND TRUCK LURCHED FORWARD CAUSING DAMAGE TO MY SUBURBAN AND ANOTHER CAR RESULTING IN AN INSURANDE SURDHARGE FOR ACCIDENT OVER $2500. DEALER, MIRAK CHEVROLET OF ARLINGTON MA COULD NOT FIND DEFECT. UPON BRAKING TODAY,I FELT A SURGE FORWARD BUT NO ACCIDENT THIS TIME. PLEASE ADVISE OF ANY PAST RECALLS OR SIMILAR INCIDENTS. *TR

NHTSA ODI #10314122

Mileage unknown · Feb 3, 2010
Service Brakes, Hydraulic

LTR FWD FM ELTON TREXLER (NC) RE DEFECTIVE RUSTY BRAKE LINES ON HIS 2002 CHEVROLET SILVERADO 2500 HD PICKUP TRUCK, INQUIRING WHY THERE IS NOT A RECALL FOR THIS ISSUE. *NJ THE CONSUMER STATED HE RECENTLY EXPERIENCED SUDDEN AND COMPLETE BRAKE FAILURE WHEN HE ATTEMPTED TO STOP. THE CONSUMER STATED HE DISCOVERED RUSTY SPOTS ON THE…

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LTR FWD FM ELTON TREXLER (NC) RE DEFECTIVE RUSTY BRAKE LINES ON HIS 2002 CHEVROLET SILVERADO 2500 HD PICKUP TRUCK, INQUIRING WHY THERE IS NOT A RECALL FOR THIS ISSUE. *NJ THE CONSUMER STATED HE RECENTLY EXPERIENCED SUDDEN AND COMPLETE BRAKE FAILURE WHEN HE ATTEMPTED TO STOP. THE CONSUMER STATED HE DISCOVERED RUSTY SPOTS ON THE BRAKE LINES AND A HOLE THAT HAD COMPLETELY RUSTED THROUGH THE LINES WHICH ALLOWED BRAKE FLUID TO ESCAPE. *JB

NHTSA ODI #10303889

Mileage unknown · Jan 8, 2010
Service Brakes, Hydraulic

FAX FROM DETECTIVE RUSTY BRAKE LINES ON HIS 2002 CHEVROLET SILVERADO PICKUP TRUCK, INQUIRING WHY THERE IS NOT A RECALL FOR THIS ISSUE. *KB THE CONSUMER STATED WHEN HE ATTEMPTED TO APPLY THE BRAKE, IT WENT COMPLETELY TO THE FLOOR. THE CONSUMER FOUND A HOLE HAD COMPLETELY RUSTED THROUGH ONE OF THE BRAKE LINES. *JB

NHTSA ODI #10299408

28,322 miles · Jan 6, 2010
Service Brakes, Hydraulic

I AM THE ORIGINAL OWNER OF A 2002 CHEVROLET SILVERADO 2500HD PICKUP TRUCK. ON 12/11/09 WHILE DRIVING THE TRUCK, I APPLIED THE BRAKES AND THE PEDAL WENT COMPLETELY TO THE FLOOR, LEAVING ME WITH NO BRAKES. FORTUNATELY, I WAS GOING VERY SLOW AT THE TIME AND WAS ABLE TO ROLL TO A SLOW STOP WITH NO DAMAGE OR INJURY. I FOUND THAT MY B…

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I AM THE ORIGINAL OWNER OF A 2002 CHEVROLET SILVERADO 2500HD PICKUP TRUCK. ON 12/11/09 WHILE DRIVING THE TRUCK, I APPLIED THE BRAKES AND THE PEDAL WENT COMPLETELY TO THE FLOOR, LEAVING ME WITH NO BRAKES. FORTUNATELY, I WAS GOING VERY SLOW AT THE TIME AND WAS ABLE TO ROLL TO A SLOW STOP WITH NO DAMAGE OR INJURY. I FOUND THAT MY BRAKE LINES WERE RUSTY WITH A HOLE ENTIRELY THROUGH ONE PLACE. I DID AN INTERNET SEARCH ON 'SILVERADO" AND 'RUSTY BRAKE LINES' AND FOUND NUMEROUS OTHER IRATE OWNERS WITH THE SAME PROBLEM. I CONTACTED GENERAL MOTORS AND WAS TOLD I WOULD NEED TO HAVE A DEALER INSPECT THE TRUCK BEFORE ANY ADDITIONAL ACTION COULD BE TAKEN. THIS IS THE RESULT: I WAS CHARGED $175.09 FOR HAULING THE VEHICLE 20 MILES TO THE NEAREST DEALER AND 'INSPECTING IT; YES, THE LINES WERE RUSTED OUT AS I HAD TOLD THEM; GENERAL MOTORS WILL PROVIDE NO FURTHER ACTION BECAUSE THE PROBLEM MAY BE THE RESULT OF 'LOW MILEAGE'; AND THE DEALER WANTS TO REPLACE THE BRAKE LINES FOR $1000.00. I LIVE IN NORTH CAROLINA AND HAVE DRIVEN AND WORKED ON VEHICLES FOR OVER 50 YEARS AND I HAVE NEVER BEFORE HAD A HOLE RUSTED IN A BRAKE LINE. THE SUDDEN AND UNEXPECTED LOSS OF BRAKES HAS TO BE A DEADLY DISASTER WAITING TO HAPPEN. *TR

NHTSA ODI #10298505

75,100 miles · Dec 21, 2009
Service Brakes, Hydraulic

ABS SLOW STOP ACTIVATION, A COMMON COMPLAINT WITH CHEVROLET TRUCKS AND SUV,S, CHEVROLET HAS REFUSED TO FIX THE PROBLEM ALTHOUGH IT IS WELL DOCUMENTED AND SOME MODELS RECALLED FOR THE SAME DEFECT. *TR

NHTSA ODI #10296644

31,000 miles · Nov 21, 2009
Service Brakes, Hydraulic

MY 2002 CHEVROLET SILVERADO 2500 HD WAS HAVING A PROBLEM WITH THE ABS SYSTEM ACTIVATING AT SLOW SPEEDS WHEN THE WHEELS WERE NOT ACTUALLY SLIDING. ALTHOUGH THE WHEELS WERE ACTING EXACTLY AS DESCRIBED IN RECALL BULLETIN 05068C, I WAS TOLD BY THE DEALER THAT MY TRUCK WAS NOT COVERED EVEN IF THE PROBLEM WAS DUE TO FRONT WHEEL SPEED…

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MY 2002 CHEVROLET SILVERADO 2500 HD WAS HAVING A PROBLEM WITH THE ABS SYSTEM ACTIVATING AT SLOW SPEEDS WHEN THE WHEELS WERE NOT ACTUALLY SLIDING. ALTHOUGH THE WHEELS WERE ACTING EXACTLY AS DESCRIBED IN RECALL BULLETIN 05068C, I WAS TOLD BY THE DEALER THAT MY TRUCK WAS NOT COVERED EVEN IF THE PROBLEM WAS DUE TO FRONT WHEEL SPEED SENSOR CORROSION AS DESCRIBED IN THE RECALL. I ALSO CALLED THE GM CUSTOMER ASSISTANCE CENTER AT 800-630-2438 WHERE THEY ALSO SAID MY TRUCK IS NOT COVERED EVEN THOUGH THE VIN IS WITHIN THE BRACKETS IN THE RECALL. I WAS GIVEN A CASE NUMBER OF 71-774131746. I TOOK MY TRUCK TO LARSON CHEVROLET IN SUPERIOR, WI ON NOVEMBER 10, 2009 WHERE THEY INSPECTED MY FRONT WHEELS AND FOUND THE CORROSION DESCRIBED IN THE RECALL. I HAD THEM REPAIR THE CORROSION AT MY EXPENSE. I THEN CONTACTED CUSTOMER ASSISTANCE AGAIN AND THEY AGREED TO FORWARD MY CASE TO A DISTRICT SPECIALIST. AFTER A COUPLE CONVERSATIONS WITH THE DISTRICT SPECIALIST ISAAC I WAS TOLD THAT MY TRUCK WOULD NOT BE COVERED BECAUSE 3/4 TON TRUCKS WERE EXCLUDED. NO REASON FOR EXCLUDING 3/4 TON TRUCKS WAS GIVEN. IT SEEMS TO ME THAT GM WAS IN ERROR WHEN 3/4 TON TRUCKS WERE EXCLUDED BECAUSE MY TRUCK HAD THE EXACT PROBLEM DESCRIBED IN THE RECALL. I WOULD LIKE TO SEE THE RECALL EXPANDED TO INCLUDE 3/4 TON TRUCKS AND TO HAVE MY EXPENSES OF $206.47 REIMBURSED. *TR

NHTSA ODI #10293135

66,284 miles · Sep 23, 2009
Service Brakes, Hydraulic

AFTER TRAVELING ON THE HIGHWAY FOR SIXTY MILES, THE TRUCK WAS BAKED FOR TRAFFIC AT HIGHWAY EXIT. THE BAKE PEDAL WENT DOWN ALMOST TO THE FLOOR. THE TRUCK DID SLOW DOWN, BUT BRAKING WAS NOT NORMAL. UPON INSPECTION IT WAS FOUND THAT THE BRAKE LINES COMING THE MASTER CYLINDER TO THE ABS AND FROM THE ABS TO THE FRONT BRAKES WERE RUST…

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AFTER TRAVELING ON THE HIGHWAY FOR SIXTY MILES, THE TRUCK WAS BAKED FOR TRAFFIC AT HIGHWAY EXIT. THE BAKE PEDAL WENT DOWN ALMOST TO THE FLOOR. THE TRUCK DID SLOW DOWN, BUT BRAKING WAS NOT NORMAL. UPON INSPECTION IT WAS FOUND THAT THE BRAKE LINES COMING THE MASTER CYLINDER TO THE ABS AND FROM THE ABS TO THE FRONT BRAKES WERE RUSTED AND ONE LINE HAD A HOLE AND WAS LEAKING. FOUR BRAKE LINES WERE REPLACED. *TR

NHTSA ODI #10284983

82,937 miles · Aug 18, 2009
Service Brakes, Hydraulic

THE REAR BRAKE LINE ON MY 2002 CHEVROLET SILVERADO 2500HD RUSTED OUT AND FAILED WHILE TOWING MY FIFTH WHEEL CAMPER.FORTUNATLY THE CAMPER BRAKES WERE FUNCTIONING PROPERLY AND I WAS ABLE TO STOP WITHOUT INCIDENT. I REMOVED AND REPLACED THE REAR BRAKE LINE WHEN I GOT THE TRUCK HOME.AS I WAS PUMPING THE BRAKES TO BLEED THE AIR OUT O…

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THE REAR BRAKE LINE ON MY 2002 CHEVROLET SILVERADO 2500HD RUSTED OUT AND FAILED WHILE TOWING MY FIFTH WHEEL CAMPER.FORTUNATLY THE CAMPER BRAKES WERE FUNCTIONING PROPERLY AND I WAS ABLE TO STOP WITHOUT INCIDENT. I REMOVED AND REPLACED THE REAR BRAKE LINE WHEN I GOT THE TRUCK HOME.AS I WAS PUMPING THE BRAKES TO BLEED THE AIR OUT OF THE NEW LINE THE RIGHT FRONT LINE FAILED.IT WAS AT THIS TIME THAT I REALIZED HOW LUCKY I WAS TO HAVE AVOIDED A POTENTIALLY DEADLY INCIDENT. UPON INSPECTION OF THE REST OF THE LINES I FOUND THEM ALL TO BE RUSTED TO THE POINT THAT I WILL BE REPLACING ALL OF THE LINES ON THE TRUCK. *TR

NHTSA ODI #10280916

35,000 miles · Aug 6, 2009
Service Brakes, HydraulicStructure

SILVERADO 2500 HD V8 BRAKE & ROTOR REPLACEMENT 37,800 MILES WE PURCHASED A BRAND NEW 2002 CHEVROLET SILVERADO HD 4 X 4 FROM FITZGERALD AUTO MALL. THE TRUCK WAS PAMPERED, NO ROUGH OFF ROAD EXCURSIONS, EVEN KEPT IT IN THE GARAGE. WITH ONLY 37,800 MILES WE WERE LITERALLY SHOCKED TO DISCOVER ALL FOUR ROTORS NOT ONLY HAD SIGNIFICA…

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SILVERADO 2500 HD V8 BRAKE & ROTOR REPLACEMENT 37,800 MILES WE PURCHASED A BRAND NEW 2002 CHEVROLET SILVERADO HD 4 X 4 FROM FITZGERALD AUTO MALL. THE TRUCK WAS PAMPERED, NO ROUGH OFF ROAD EXCURSIONS, EVEN KEPT IT IN THE GARAGE. WITH ONLY 37,800 MILES WE WERE LITERALLY SHOCKED TO DISCOVER ALL FOUR ROTORS NOT ONLY HAD SIGNIFICANT RUST BUT METAL WAS ACTUALLY CHIPPING, FLAKING, AND CRUMBLING FROM THE ROTORS. ALL FOUR ROTORS HAD TO BE REPLACED ALONG WITH THE BRAKE PADS. THE PADS HAD WORN BUT NOT [REPEAT NOT] DOWN TO THE "WEAR SENSORS" AND WERE REPLACED FOR SAFETY REASONS. THE COST FOR THE REPAIR WAS $1,150.00. WE HAVE OTHER VEHICLES "NONE OF THEM MANUFACTURED BY GM" AND NEVER EXPERIENCED THIS TYPE OF WEAR OR DAMAGE TO ROTORS. THE ONLY SAFETY RECALL WE WERE ADVISED OF AFFECTED THE TAILGATE CABLES. THE TAILGATE CABLES PREMATURELY CORRODED AND FAILED. THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION SHOULD BE ALERTED AS THIS POSES A SIGNIFICANT SAFETY RISK FOR ANYONE WHO UNWITTINGLY EXPERIENCES THIS PROBLEM. LEFT UNDETECTED THESE ROTORS WOULD HAVE FAILED CAUSING AN ABSOLUTE AND SUDDEN LOSS OF BRAKING CAPACITY. IF FORD MOTOR COMPANY HAD TO ACCEPT RESPONSIBILITY FOR RECALLING MILLIONS OF UNSAFE FIRESTONE TIRES - WHY HASN'T THIS PROBLEM BEEN ADDRESSED BY GM? *TR

NHTSA ODI #10279619

78,000 miles · Jul 22, 2009
Service Brakes, Hydraulic

2002 CHEVROLET 2500HD PICKUP TRUCK. WHILE MY DAUGHTER WAS DRIVING THE TRUCK, BOTH STEEL BRAKE LINES FROM THE MASTER CYLINDER FAILED CAUSING TOTAL LOSS OF BRAKES. TRUCK WAS TOWED TO DUNLAP-JOHNSON CHEVROLET CO.,INC. 919 E LIBERTY ST , YORK, SC 29745-2689 (803) 792-4152. CHEVROLET WAS CALLED AT 1-800-222-1020 AND CASE # 71-742-7…

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2002 CHEVROLET 2500HD PICKUP TRUCK. WHILE MY DAUGHTER WAS DRIVING THE TRUCK, BOTH STEEL BRAKE LINES FROM THE MASTER CYLINDER FAILED CAUSING TOTAL LOSS OF BRAKES. TRUCK WAS TOWED TO DUNLAP-JOHNSON CHEVROLET CO.,INC. 919 E LIBERTY ST , YORK, SC 29745-2689 (803) 792-4152. CHEVROLET WAS CALLED AT 1-800-222-1020 AND CASE # 71-742-720900 WAS OPENED. I WAS CONTACTED ON JULY 21 BY CAROLINE LUCERO FROM CHEVROLET WHO STATED THAT THE BRAKE LINES FAILED BECAUSE OF ENVIRONMENTAL CONDITIONS IN THE NE UNITED STATES. HAVING BRAKE LINES THAT CAN FAIL WITHOUT WARNING CAUSING THE BRAKE PEDAL TO GO TO THE FLOORBOARD WHILE PROVIDING NO STOPPING EFFORT IS A VERY DANGEROUS SITUATION. THANKFULLY NO ONE WAS INJURED IN THIS INSTANCE; HOWEVER I SUSPECT THAT THE BRAKE LINE FAILURE IS PREMATURE BASED ON THE AGE AND MILEAGE OF THE VEHICLE AND POSSIBLY CAUSED BY DEFECTIVE MATERIALS. I AM SAVING THE BRAKE LINES IN CASE THEY ARE WANTED FOR TESTING OR INSPECTION. *TR

NHTSA ODI #10277947

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.