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2002 Chevrolet Silverado

Owner reports · Recalls · Investigations

More warning signs than most Silverado years

Owner complaints for the 2002 Chevrolet Silverado are substantially higher than the model-year median of 76.

About this comparison →

When problems were reported

Mileage at the reported incident

495 reports with mileage · 215 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 245 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Power Train. Review the 70 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes. Review the 70 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

75 crash reports5 fire reports31 injury reports

What owners actually said

710 reports
36,500 miles · Sep 8, 2005
Service Brakes, Hydraulic

WHEN THE VEHICLE IS SLOWING TO A STOP AND ALMOST STOPPED THE ABS ACTIVATE AND CAUSE THE VEHICLE TO CONTINUE COASTING. THERE HAVE BEEN SEVERAL NEAR ACCIDENTS HOWEVER, LUCKILY NO COLLISIONS HAVE HAPPENED YET. THE VEHICLE IS SCHEDULED TO GO INTO THE SHOP FOR REPAIR ON SEPTEMBER 16TH. THE PROBLEM IS CONTINUOUS AND HAPPENS ABOUT 5 OU…

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WHEN THE VEHICLE IS SLOWING TO A STOP AND ALMOST STOPPED THE ABS ACTIVATE AND CAUSE THE VEHICLE TO CONTINUE COASTING. THERE HAVE BEEN SEVERAL NEAR ACCIDENTS HOWEVER, LUCKILY NO COLLISIONS HAVE HAPPENED YET. THE VEHICLE IS SCHEDULED TO GO INTO THE SHOP FOR REPAIR ON SEPTEMBER 16TH. THE PROBLEM IS CONTINUOUS AND HAPPENS ABOUT 5 OUT OF 10 STOPS. *JB

NHTSA ODI #10135769

40,200 miles · Sep 7, 2005
Service Brakes, HydraulicSuspension

THE ABS COMES ON AT LOW SPEED WHEN IT SHOULDN'T, RESULTING IN EXTENDING STOPPING DISTANCE. DEALER MISS DIAGNOSED THE PROBLEM AS THE LEFT FRONT HUB. REPLACING BOTH FRONT HUBS AND WHEEL SPEED SENSORS WHICH FIXED THE PROBLEM. *AK

NHTSA ODI #10136663

45,624 miles · Sep 6, 2005
Service Brakes, Hydraulic

DT: THE CONSUMER STATED THAT SHE WAS HAVING A PROBLEM WITH 2002 CHEVROLET SILVERADO. THE ABS SYSTEM KICKED IN AT LOW SPEEDS OF 0-10 MPH. THIS HAPPENED WHEN THE TRUCK WAS SLOWING DOWN OR COMING TO A STOP. THIS HAS BEEN HAPPENING SINCE MAY 2005 INTERMITTENTLY. THE CONSUMER HAD THE ABS SENSORS CLEANED, AND THE TRUCK WAS DR…

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DT: THE CONSUMER STATED THAT SHE WAS HAVING A PROBLEM WITH 2002 CHEVROLET SILVERADO. THE ABS SYSTEM KICKED IN AT LOW SPEEDS OF 0-10 MPH. THIS HAPPENED WHEN THE TRUCK WAS SLOWING DOWN OR COMING TO A STOP. THIS HAS BEEN HAPPENING SINCE MAY 2005 INTERMITTENTLY. THE CONSUMER HAD THE ABS SENSORS CLEANED, AND THE TRUCK WAS DRIVING MUCH BETTER AFTER THE CLEANING. THE DEALER HAS NOT BEEN CONTACTED BECAUSE THE VEHICLE WAS OUT OF WARRANTY. THE MANUFACTURER WAS CONTACTED, AND THEY TOLD THE CONSUMER THAT THIS TRUCK WAS NOT INCLUDED IN THE RECALL CURRENTLY. GENERAL MOTORS TOLD THE MECHANIC AT THE REPAIR SHOP TO JUST CLEAN THE SENSORS INSTEAD OF REPLACING THEM. THIS WAS AT CONSUMER'S EXPENSE. *AK

NHTSA ODI #10135440

33,000 miles · Sep 1, 2005
Vehicle Speed Control

I HAVE A 2002 SILVERADO CHEVROLET 1500 SHORT BED (~50K MI) WITH A STICKING THROTTLE BODY. I HAVE APPROACHED ELDORADO CHEVROLET TWICE ABOUT HAVING THE PROBLEM REMEDIED. THEY HAVE TOLD ME THAT CLEANING THE THROTTLE BODY IS A ROUTINE MAINTENANCE ISSUE- AND THAT IT IS MY RESPONSIBILITY TO TAKE CARE OF THIS. THE THING IS, THE OWNE…

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I HAVE A 2002 SILVERADO CHEVROLET 1500 SHORT BED (~50K MI) WITH A STICKING THROTTLE BODY. I HAVE APPROACHED ELDORADO CHEVROLET TWICE ABOUT HAVING THE PROBLEM REMEDIED. THEY HAVE TOLD ME THAT CLEANING THE THROTTLE BODY IS A ROUTINE MAINTENANCE ISSUE- AND THAT IT IS MY RESPONSIBILITY TO TAKE CARE OF THIS. THE THING IS, THE OWNER'S MANUAL DOES NOT GIVE A MILEAGE OR TIME FRAME IN WHICH THIS ITEM SHOULD BE INSPECTED AND/ OR CLEANED!! I'VE READ NUMEROUS CONSUMER REPORTS AND TESTIMONIALS FROM OTHER CHEVY OWNERS COMPLAINING OF THE SAME PROBLEM. GM CUSTOMER SERVICE TELLS ME THAT ADDITIVES IN THE GASOLINE IN MY AREA (NORTH TEXAS) CAUSE CARBON TO BUILD UP IN THE THROTTLE BODY CAUSING THE GAS PEDAL TO STICK. I HAVE SEVERAL FRIENDS WHO LIVE IN MY AREA AND WHO OWN CHEVROLET PICKUPS. NONE OF THEM HAVE A PROBLEM WITH THEIR GAS PEDAL STICKING!! THIS IS A SERIOUS PROBLEM FOR WHICH GM NEEDS TO TAKE RESPONSIBILITY! IF I DO CLEAN THE THROTTLE BODY, THE PROBLEM IS LIKELY TO REOCCUR. I GUESS GM WILL SUGGEST I LOBBY TO HAVE THE TEXAS OIL PRODUCERS CHANGE THE CHEMICAL MAKEUP OF THEIR PETROLEUM PRODUCTS!! I HOPE MORE PEOPLE EXPERIENCING THIS PROBLEM COME FORWARD- I FEEL THIS SHOULD DEFINITELY BE A RECALL ISSUE. THANK YOU, ROBERT LAUGHON. *NM

NHTSA ODI #10135053

36,000 miles · Aug 31, 2005
Service Brakes, Hydraulic

DT: CONSUMER COMPLAINED ABOUT A FRONT BRAKE PROBLEM. THE PROBLEM STARTED ON 7-22-05. WHILE COMING TO A STOP AT 4-5 MPH THE BRAKES FAILED. THIS OCCURRED EVERY TIME THE CONSUMER APPLIED PRESSURE TO THE BRAKES. THERE WERE NO ACCIDENTS. THE CONSUMER HAS MADE THE NECESSARY REPAIRS TO THE VEHICLE HIMSELF. HE DID SO BECAUSE HE …

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DT: CONSUMER COMPLAINED ABOUT A FRONT BRAKE PROBLEM. THE PROBLEM STARTED ON 7-22-05. WHILE COMING TO A STOP AT 4-5 MPH THE BRAKES FAILED. THIS OCCURRED EVERY TIME THE CONSUMER APPLIED PRESSURE TO THE BRAKES. THERE WERE NO ACCIDENTS. THE CONSUMER HAS MADE THE NECESSARY REPAIRS TO THE VEHICLE HIMSELF. HE DID SO BECAUSE HE COULD NOT DRIVE THE VEHICLE UNLESS IT WAS REPAIRED. WHEN THE CONSUMER CONTACTED THE MANUFACTURER, THEY TOLD HIM THEY WOULD NOT ASSIST HIM BECAUSE HE REPAIRED THE VEHICLE HIMSELF. ALSO,THEY TOLD HIM THIS VEHICLE WAS NOT INCLUDED IN ANY RECALLS. *AK

NHTSA ODI #10134988

55,000 miles · Aug 31, 2005
Service Brakes, Hydraulic

ANTI-LOCK BRAKES ENGAGE AT LOW SPEEDS MANY TIMES. NEAR MISS ACCIDENT. GM HAS A RECALL FOR THIS PROBLEM IN COLD WEATHER STATES BUT NOT WISCONSIN. HOW CAN WISCONSIN NOT BE A COLD WEATHER STATE WHEN ILLINOIS IS SOUTH OF US AND IT WAS INCLUDED IN THE RECALL. I PAID A DEALER TO REPAIR THIS PROBLEM AND I WANT MY MONEY BACK.*JB

NHTSA ODI #10134926

47,000 miles · Aug 30, 2005
Service Brakes, Hydraulic

I OWN A 2002 CHEVY SILVERADO 1 TON DUAL WHEEL PICK UP - EXTENDED CAB. FOR THE LAST 8 MONTHS I HAVE BEEN HAVING PROBLEMS WITH THE ANTI LOCK BRAKES PULSATING AT LOW SPEEDS (UNDER 10 MPH WHEN I AM TRYING TO STOP. I WAS PREVIOUSLY INJURED IN AN AUTOMOBILE ACCIDENT AND HAVE OVER 12 DISKS IN MY NECK, MID AND LOWER BACK, I AM CLASS…

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I OWN A 2002 CHEVY SILVERADO 1 TON DUAL WHEEL PICK UP - EXTENDED CAB. FOR THE LAST 8 MONTHS I HAVE BEEN HAVING PROBLEMS WITH THE ANTI LOCK BRAKES PULSATING AT LOW SPEEDS (UNDER 10 MPH WHEN I AM TRYING TO STOP. I WAS PREVIOUSLY INJURED IN AN AUTOMOBILE ACCIDENT AND HAVE OVER 12 DISKS IN MY NECK, MID AND LOWER BACK, I AM CLASSIFIED AS TOTALLY AND PERMANENTLY DISABLED. THIS TRUCK IS MY ONLY MEANS OF TRANSPORTATION TO AND FROM DOCTOR APPTS AND MEDICAL TREATMENT, I HAVE CONTACTED MY DEALERSHIP ABOUT THE PROBLEM AND WAS ADVISED THAT ONLY VEHICLES IN CANADA WERE BEING RECALLED FOR THIS PROBLEM, IF I WANTED IT FIXED IT WOULD COST APPROX. $350.00. I NOW LIVE ON SSI DISABILITY AND ONLY RECEIVE $841.00 PER MONTH, I CANNOT AFFORD TO HAVE THIS VEHICLE FIXED AND THE PROBLEM IS GETTING WORSE EVERY DAY. IT HAS HAPPENED WELL OVER 1000 TIMES AND PRETTY MUCH DOES IT NOW EVER TIME I PUSH THE BRAKE PEDAL. WHAT AM I SUPPOSED TO DO??? DO I JUST WAIT UNTIL I LOSE CONTROL OF MY VEHICLE WHILE BRAKING AND HIT SOMEONE CAUSING MORE DAMAGE TO MYSELF AND POSSIBLE ANOTHER INNOCENT PERSON OR ARE YOU GOING TO FORCE GM TO FIX THIS DISASTER? PLEASE ADVISE ME OF MY OPTIONS AND WHAT I SO DO OR WHOM I SHOULD CONTACT - I NEED MY TRUCK FIXED! *JB

NHTSA ODI #10134818

18,000 miles · Aug 30, 2005
Service Brakes, Hydraulic

I JUST HEARD OF GM'S RECALL ON ABS BRAKING SYSTEMS. I HAVE A 02 SILVERADO THAT HAS HAD THIS SAME PROBLEM TWO SEPARATE TIMES. WHEN THE BRAKES WERE APPLIED IT FELT LIKE NO PEDAL THEN IT WOULD PULSATE. WHICH YOU COULD FEEL THROUGH THE PEDAL. BOTH TIMES THE DEALERSHIP SAID THE SENSORS WERE TO BLAME. THE SECOND TIME IT HAPPENED T…

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I JUST HEARD OF GM'S RECALL ON ABS BRAKING SYSTEMS. I HAVE A 02 SILVERADO THAT HAS HAD THIS SAME PROBLEM TWO SEPARATE TIMES. WHEN THE BRAKES WERE APPLIED IT FELT LIKE NO PEDAL THEN IT WOULD PULSATE. WHICH YOU COULD FEEL THROUGH THE PEDAL. BOTH TIMES THE DEALERSHIP SAID THE SENSORS WERE TO BLAME. THE SECOND TIME IT HAPPENED THEY DID NOT WANT TO FIX WITHOUT PAY. SINCE IT HAD HAPPENED A COUPLE MONTHS EARLIER. *JB

NHTSA ODI #10134816

38,227 miles · Aug 30, 2005
Power Train

DT: CONTACT OWNED A 2002 CHEVROLET SILVERADO. WHILE DRIVING CONSUMER'S VEHICLE BEGAN TO PASS ANOTHER VEHICLE. WHEN THE VEHICLE WENT INTO PASSING GEAR CONSUMER HEARD A LOUD NOISE. CONSUMER LET OFF THE GAS AND THE VEHICLE SHIFTED INTO ANOTHER GEAR. WHILE TAKING THE VEHICLE TO THE GARAGE CONSUMER REALIZED THERE WAS NO REVER…

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DT: CONTACT OWNED A 2002 CHEVROLET SILVERADO. WHILE DRIVING CONSUMER'S VEHICLE BEGAN TO PASS ANOTHER VEHICLE. WHEN THE VEHICLE WENT INTO PASSING GEAR CONSUMER HEARD A LOUD NOISE. CONSUMER LET OFF THE GAS AND THE VEHICLE SHIFTED INTO ANOTHER GEAR. WHILE TAKING THE VEHICLE TO THE GARAGE CONSUMER REALIZED THERE WAS NO REVERSE AND IT WAS SHIFTING ODDLY. THE SERVICE DEALER STATED THE TRANSMISSION WILL HAVE TO BE REPAIRED, BUT DID NOT KNOW THE CAUSE OF THE TRANSMISSION FAILURE. THERE HAD BEEN NO PREVIOUS PROBLEMS REGARDING THE TRANSMISSION AND THE VEHICLE HAS MINIMAL USAGE. THE WARRANTY OF THE VEHICLE WAS FOR 3 YEARS/36,000 MILES, THE VEHICLE HAS APPROXIMATELY 38,000 MILES WHEN THIS INCIDENT OCCURRED.*AK

NHTSA ODI #10131530

45,034 miles · Aug 29, 2005
Suspension

DT: A NOISE WAS COMING FROM THE DRIVER'S SIDE FRONT WHEEL AREA. THE CONSUMER NOTICED IT WHEN TURNING THE VEHICLE AT SLOW SPEEDS. WHEN THE CONSUMER TOOK IT TO THE DEALER THEY DID NOT HEAR THE NOISE, AND DID NOTHING TO SOLVE THE PROBLEM THE CONSUMER WAS UNSURE OF THE EXACT PROBLEM. IT FIRST STARTED OCCURRING ON 7-14-05. *AK

NHTSA ODI #10134673

Official recalls

4

05V379000 · Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip

Aug 29, 2005

CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES MAY EXPERIENCE UNWANTED ANTILOCK BRAKE SYSTEM (ABS) ACTIVATION. THIS CONDITION IS MORE LIKELY TO OCCUR IN ENVIRONMENTALLY CORROSIVE AREAS. THIS RECALL WILL BE LAUNCHED IN THE "SALT BELT" STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MARYLAND, MASSACHUSETTS, MAINE, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN AND THE DISTRICT OF COLUMBIA ONLY.

Consequence & remedy

Consequence: THIS CAN CAUSE INCREASED STOPPING DISTANCES DURING LOW-SPEED BRAKE APPLICATIONS, WHICH COULD RESULT IN A CRASH.

Remedy: DEALERS ARE TO REMOVE THE WHEEL SPEED SENSOR AND THOROUGHLY CLEAN THE WHEEL SPEED SENSOR MOUNTING SURFACE ON THE BEARING, APPLY RUST INHIBITOR TO THE CLEANED SURFACE, GREASE THE MOUNTING SURFACE, REINSTALL THE WHEEL SPEED SENSOR, AND CHECK THE PEAK-TO-PEAK OUTPUT VOLTAGE TO ENSURE THE WHEEL SPEED SIGNAL IS WITHIN SPECIFICATIONS. THE RECALL BEGAN SEPTEMBER 22, 2005. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438 OR GMC AT 1-866-996-9463.

05V161000 · Parking Brake

Apr 22, 2005

ON CERTAIN PICKUP TRUCKS EQUIPPED WITH MANUAL TRANSMISSIONS AND BUILT WITH EITHER PBR PARKING BRAKE SYSTEMS OR TRW PARKING BRAKE SYSTEMS, THE PARKING BRAKE FRICTION LININGS MAY WEAR TO AN EXTENT WHERE THE PARKING BRAKE CAN BECOME INEFFECTIVE IN IMMOBILIZING A PARKED VEHICLE.

Consequence & remedy

Consequence: IF THE PARKING BRAKE DOES NOT HOLD, UNINTENDED VEHICLE MOVEMENT COULD OCCUR, WHICH COULD RESULT IN A CRASH.

Remedy: DEALERS WILL INSTALL A LOW-FORCE SPRING CLIP RETAINER FOR VEHICLES EQUIPPED WITH A PBR PARKING BRAKE SYSTEM. ON VEHICLES EQUIPPED WITH THE TRW PARKING BRAKE SYSTEM, DEALERS WILL INSTALL A REDESIGNED PARKING BRAKE CABLE ASSEMBLY. THE RECALL BEGAN ON JULY 29, 2005. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438 OR GMC AT 1-866-996-9463.

04V129000 · Structure:body:tailgate:hinge And Attachments

Mar 17, 2004

ON CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES, THE GALVANIZED STEEL TAILGATE SUPPORT CABLES THAT RETAIN THE TAILGATE IN THE FULL OPEN (HORIZONTAL) POSITION MAY CORRODE, WEAKEN, AND EVENTUALLY FRACTURE. IF BOTH CABLES FRACTURED, THE TAILGATE WOULD SUDDENLY DROP AND STRIKE THE TOP SURFACE OF THE REAR BUMPER.

Consequence & remedy

Consequence: ANYONE SITTING OR STANDING ON THE HORIZONTAL SURFACE OF THE TAILGATE WHEN BOTH CABLES FRACTURED COULD BE INJURED BY FALLING FROM THE TAILGATE. ON VEHICLES THAT HAVE HAD THE BUMPER REMOVED, THE TAILGATE MAY DROP EVEN LOWER. ADDITIONALLY, IF THERE IS CARGO ON THE TAILGATE THE CARGO MAY FALL OFF IF THE SUPPORT CABLES FRACTURE.

Remedy: DEALERS WILL REPLACE THE CABLES. INTERIM OWNER NOTIFICATION BEGAN ON APRIL 7, 20004. THE RECALL BEGAN ON SEPTEMBER 24, 2004, WHEN REPLACEMENT PARTS WERE AVAILABLE, AND WILL CONTINUE THROUGH OCTOBER 29, 2004. OWNERS SHOULD CONTACT CADILLAC AT 1-866-982-2339, CHEVROLET AT 1-800-630-2438 OR GMC AT 1-866-996-9463, OR VISIT WWW.MYGMLINK.COM, AND ENTER YOUR VEHICLE IDENTIFICATION NUMBER.

03V435000 · Fuel System, Other:delivery

Nov 3, 2003

SOME 2WD AND 4WD PICKUP TRUCKS, CONVERTED TO EITHER DEDICATED OR BI-FUEL COMPRESSED NATURAL GAS (CNG) FUEL USAGE, WERE ASSEMBLED WITH A THROTTLE CABLE THAT CAN CONTACT AND RUB THROUGH THE FLEXIBLE PRESSURIZED FUEL LINE CREATING A PINHOLE LEAK OF NATURAL GAS TO THE ATMOSPHERE.

Consequence & remedy

Consequence: A STRONG ODOR OF NATURAL GAS MAY BE DETECTED FROM INSIDE THE VEHICLE, POSSIBLY ACCOMPANIED BY A HISSING NOISE. IF THE NATURAL GAS WERE ACCIDENTALLY IGNITED, SERIOUS INJURY COULD RESULT.

Remedy: DEALERS WILL SECURE THE THROTTLE CABLE TO ELIMINATE THE POSSIBILITY OF CONTACT WITH THE CNG FUEL LINE. THE CNG FUEL LINE, THROTTLE CABLE, AND CRUISE CONTROL CABLE ARE ALSO TO BE INSPECTED AND REPLACED IF NECESSARY. OWNER NOTIFICATION BEGAN ON DECEMBER 11, 2003. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438 OR GMC AT 1-866-996-9463.

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

12

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

PE10010 · Brake Line Corrosion Failure

Opened Mar 30, 2010 · Closed Jan 5, 2011

Status: closed (inferred from source dates) · Service Brakes, Hydraulic; Service Brakes, Hydraulic:power Assist:hydraulic:hoses, Lines/piping, And Fittings

The Office of Defects Investigation (ODI) received Defect Petition DP10-003 on March 2, 2010, requesting the investigation of model year (MY) 2003 Chevrolet Silverado 2500HD 4WD pickup trucks for corrosion failures of the vehicle brake lines.DP10-003 was granted and on March 30, 2010, Preliminary Evaluation PE10-010 was opened on more than six million model year 1999 through 2003 light trucks and sport utility vehicles manufactured and sold by General Motors Corporation (GM).On July 2, 2010, ODI received GM's response to an information request, which included GM's assessment of the frequency and safety consequences of the alleged defect. GM stated that:(1) the brake system of the subject vehicles is split front/rear and should a brake pipe suddenly fail for any reason, the affected vehicle would be capable of stopping with the pressure supplied by the remaining circuit; (2) the subject vehicles were designed to meet the hydraulic circuit partial failure requirements of Federal Motor Vehicle Safety Standards 105 and 135, Light Vehicle Brake Systems; and (3) should a brake fluid leak occur for any reason, the brake system malfunction indicator lamp (MIL) would illuminate and warn the driver before the brake fluid level was low enough to cause a loss of line pressure.ODI's and GM's analysis indicates that 85 percent of the complaints occurred on vehicles used primarily in States that use salt on the roads during Winter months (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).Overall the complaint rates per 100,000 vehicles for Salt Belt States is 43.0 and Non-Salt Belt is 3.0.In approximately 25 percent of the complaints the brake pipe failure occurred suddenly, with no warning (i.e., no MIL, Brake Fluid Loss Warning), and resulted in extended stopping distances.In 30 of these the increase in stopping distance that resulted was a factor in the crash and in 10 others the vehicle was intentionally steered off the road or into another lane of travel in order to avoid a crash.This investigation has been upgraded to an Engineering Analysis (EA11-001) for subject vehicles sold or currently registered in Salt Belt States to further assess the scope, frequency and safety risks associated with sudden failures of corroded brake pipes that can result in decreased brake effectiveness. ODI will continue to gather information on subject vehicles outside the Salt Belt as well.

Additional source detail variants (2)

Service Brakes, Hydraulic

The Office of Defects Investigation (ODI) received Defect Petition DP10-003 on March 2, 2010, requesting the investigation of model year (MY) 2003 Chevrolet Silverado 2500HD 4WD pickup trucks for corrosion failures of the vehicle brake lines.DP10-003 was granted and on March 30, 2010, Preliminary Evaluation PE10-010 was opened on more than six million model year 1999 through 2003 light trucks and sport utility vehicles manufactured and sold by General Motors Corporation (GM).On July 2, 2010, ODI received GM's response to an information request, which included GM's assessment of the frequency and safety consequences of the alleged defect. GM stated that:(1) the brake system of the subject vehicles is split front/rear and should a brake pipe suddenly fail for any reason, the affected vehicle would be capable of stopping with the pressure supplied by the remaining circuit; (2) the subject vehicles were designed to meet the hydraulic circuit partial failure requirements of Federal Motor Vehicle Safety Standards 105 and 135, Light Vehicle Brake Systems; and (3) should a brake fluid leak occur for any reason, the brake system malfunction indicator lamp (MIL) would illuminate and warn the driver before the brake fluid level was low enough to cause a loss of line pressure.ODI's and GM's analysis indicates that 85 percent of the complaints occurred on vehicles used primarily in States that use salt on the roads during Winter months (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).Overall the complaint rates per 100,000 vehicles for Salt Belt States is 43.0 and Non-Salt Belt is 3.0.In approximately 25 percent of the complaints the brake pipe failure occurred suddenly, with no warning (i.e., no MIL, Brake Fluid Loss Warning), and resulted in extended stopping distances.In 30 of these the increase in stopping distance that resulted was a factor in the crash and in 10 others the vehicle was intentionally steered off the road or into another lane of travel in order to avoid a crash.This investigation has been upgraded to an Engineering Analysis (EA11-001) for subject vehicles sold or currently registered in Salt Belt States to further assess the scope, frequency and safety risks associated with sudden failures of corroded brake pipes that can result in decreased brake effectiveness. ODI will continue to gather information on subject vehicles outside the Salt Belt as well.

Service Brakes, Hydraulic:power Assist:hydraulic:hoses, Lines/piping, And Fittings

The Office of Defects Investigation (ODI) received Defect Petition DP10-003 on March 2, 2010, requesting the investigation of model year (MY) 2003 Chevrolet Silverado 2500HD 4WD pickup trucks for corrosion failures of the vehicle brake lines.DP10-003 was granted and on March 30, 2010, Preliminary Evaluation PE10-010 was opened on more than six million model year 1999 through 2003 light trucks and sport utility vehicles manufactured and sold by General Motors Corporation (GM).On July 2, 2010, ODI received GM's response to an information request, which included GM's assessment of the frequency and safety consequences of the alleged defect. GM stated that:(1) the brake system of the subject vehicles is split front/rear and should a brake pipe suddenly fail for any reason, the affected vehicle would be capable of stopping with the pressure supplied by the remaining circuit; (2) the subject vehicles were designed to meet the hydraulic circuit partial failure requirements of Federal Motor Vehicle Safety Standards 105 and 135, Light Vehicle Brake Systems; and (3) should a brake fluid leak occur for any reason, the brake system malfunction indicator lamp (MIL) would illuminate and warn the driver before the brake fluid level was low enough to cause a loss of line pressure.ODI's and GM's analysis indicates that 85 percent of the complaints occurred on vehicles used primarily in States that use salt on the roads during Winter months (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).Overall the complaint rates per 100,000 vehicles for Salt Belt States is 43.0 and Non-Salt Belt is 3.0.In approximately 25 percent of the complaints the brake pipe failure occurred suddenly, with no warning (i.e., no MIL, Brake Fluid Loss Warning), and resulted in extended stopping distances.In 30 of these the increase in stopping distance that resulted was a factor in the crash and in 10 others the vehicle was intentionally steered off the road or into another lane of travel in order to avoid a crash.This investigation has been upgraded to an Engineering Analysis (EA11-001) for subject vehicles sold or currently registered in Salt Belt States to further assess the scope, frequency and safety risks associated with sudden failures of corroded brake pipes that can result in decreased brake effectiveness. ODI will continue to gather information on subject vehicles outside the Salt Belt as well.

PE06016 · Crank Position Sensor Failure - Stall

Opened May 4, 2006 · Closed Sep 14, 2006

Status: closed (inferred from source dates) · Engine And Engine Cooling; Engine And Engine Cooling:engine

THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE06-016) ON MAY 4, 2006 BASED ON ELEVEN VEHICLE OWNER QUESTIONNAIRES (VOQS) AND EARLY WARNING (EWR) DATA ALLEGING SUDDEN ENGINE SHUTDOWN WHILE DRIVING AS A RESULT OF CRANK POSITION SENSOR FAILURES IN MY 2001-2002 GENERAL MOTORS C/K PLATFORM VEHICLES EQUIPPED WITH 8.1L ENGINES.IN RESPONSE TO AN INFORMATION REQUEST LETTER SENT BY ODI, GENERAL MOTORS (GM) PROVIDED OWNER COMPLAINT INFORMATION, FIELD REPORTS AND WARRANTY CLAIM DATA BASED ON A POPULATION OF 108,338 VEHICLES. THE DATA WAS CATEGORIZED BY ENGINE STALLS WHILE DRIVING, ENGINE STALLS WITH AN UNKNOWN DRIVING CONDITION, NO START CONDITIONS AND CLAIMS WHERE IT WAS INDETERMINATE IF AN ENGINE STALL OCCURRED WHILE DRIVING.GENERAL MOTOR'S RESPONSE INCLUDED 1,213 OWNER COMPLAINTS AND FIELD REPORTS OF WHICH 289 WERE CATEGORIZED AS ENGINE STALLS WHILE DRIVING ALLEGEDLY CAUSED BY CRANK POSITION SENSOR FAILURES. GENERAL MOTORS ALSO SUBMITTED WARRANTY CLAIMS FROM ITS REGULAR WARRANTY (5 YEARS/50,000 MILES) AND FROM ITS EXTENDED WARRANTY DATABASE. FROM THE REGULAR WARRANTY DATABASE THERE WERE 3,140 CLAIMS OF CRANK POSITION SENSOR REPLACEMENT OF WHICH 147 CLAIMS WERE FROM CONSUMERS ALLEGING ENGINE STALL WHILE DRIVING.GM STATED THAT 2,841 OF THE CLAIMS WERE INDETERMINATE IF AN ENGINE STALL OCCURRED WHILE DRIVING.FROM ITS EXTENDED WARRANTY DATABASE, GM SUBMITTED 1,561 CLAIMS OF CRANK POSITION SENSOR FAILURE THAT IT ALSO STATED WERE INDETERMINATE AS TO WHETHER AN ENGINE STALL OCCURRED WHILE DRIVING.IN TOTAL, GM REPORTS 4,701 CLAIMS OF CRANK POSITION SENSOR FAILURE COMBINING REGULAR WARRANTY AND EXTENDED WARRANTY.SIMILAR TO GM'S STATISTICAL ANALYSIS, ODI'S ANALYSIS SHOWED THAT THE FAILURE RATE FOR WARRANTY CLAIMS OF ENGINE STALL WHILE DRIVING AT THREE YEARS IN SERVICE IS LOW (LESS THAN 1%).HOWEVER, FURTHER ANALYSIS DETERMINED THAT THE MY 2001 VEHICLE BUILD PERIOD FROM MAY 2000 THROUGH OCTOBER 2000 HAD SIGNIFICANTLY HIGHER (MORE THAN FOUR TIMES) CRANK POSITION FAILURE RATES IN BOTH CONSUMER COMPLAINT DATA AND WARRANTY CLAIM DATA THAN IN THE BUILD PERIOD FROM NOVEMBER 2000 THROUGH JULY 2001.ADDING THE CLAIMS OF KNOWN ENGINE STALL WHILE DRIVING AND CLAIMS WHERE ENGINE STALL WAS INDETERMINATE, THE FAILURE RATE AT THREE YEARS IN SERVICE FOR THIS POPULATION IS OVER 6%.AN ENGINEERING ANALYSIS (EA06-016) HAS BEEN OPENED TO FURTHER ASSESS THE FREQUENCY AND POTENTIAL SAFETY CONSEQUENCES ASSOCIATED WITH THE ALLEGED DEFECT IN VEHICLES BUILT FROM MAY 2000 THROUGH OCTOBER 2000.

Additional source detail variants (2)

Engine And Engine Cooling:engine

THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE06-016) ON MAY 4, 2006 BASED ON ELEVEN VEHICLE OWNER QUESTIONNAIRES (VOQS) AND EARLY WARNING (EWR) DATA ALLEGING SUDDEN ENGINE SHUTDOWN WHILE DRIVING AS A RESULT OF CRANK POSITION SENSOR FAILURES IN MY 2001-2002 GENERAL MOTORS C/K PLATFORM VEHICLES EQUIPPED WITH 8.1L ENGINES.IN RESPONSE TO AN INFORMATION REQUEST LETTER SENT BY ODI, GENERAL MOTORS (GM) PROVIDED OWNER COMPLAINT INFORMATION, FIELD REPORTS AND WARRANTY CLAIM DATA BASED ON A POPULATION OF 108,338 VEHICLES. THE DATA WAS CATEGORIZED BY ENGINE STALLS WHILE DRIVING, ENGINE STALLS WITH AN UNKNOWN DRIVING CONDITION, NO START CONDITIONS AND CLAIMS WHERE IT WAS INDETERMINATE IF AN ENGINE STALL OCCURRED WHILE DRIVING.GENERAL MOTOR'S RESPONSE INCLUDED 1,213 OWNER COMPLAINTS AND FIELD REPORTS OF WHICH 289 WERE CATEGORIZED AS ENGINE STALLS WHILE DRIVING ALLEGEDLY CAUSED BY CRANK POSITION SENSOR FAILURES. GENERAL MOTORS ALSO SUBMITTED WARRANTY CLAIMS FROM ITS REGULAR WARRANTY (5 YEARS/50,000 MILES) AND FROM ITS EXTENDED WARRANTY DATABASE. FROM THE REGULAR WARRANTY DATABASE THERE WERE 3,140 CLAIMS OF CRANK POSITION SENSOR REPLACEMENT OF WHICH 147 CLAIMS WERE FROM CONSUMERS ALLEGING ENGINE STALL WHILE DRIVING.GM STATED THAT 2,841 OF THE CLAIMS WERE INDETERMINATE IF AN ENGINE STALL OCCURRED WHILE DRIVING.FROM ITS EXTENDED WARRANTY DATABASE, GM SUBMITTED 1,561 CLAIMS OF CRANK POSITION SENSOR FAILURE THAT IT ALSO STATED WERE INDETERMINATE AS TO WHETHER AN ENGINE STALL OCCURRED WHILE DRIVING.IN TOTAL, GM REPORTS 4,701 CLAIMS OF CRANK POSITION SENSOR FAILURE COMBINING REGULAR WARRANTY AND EXTENDED WARRANTY.SIMILAR TO GM'S STATISTICAL ANALYSIS, ODI'S ANALYSIS SHOWED THAT THE FAILURE RATE FOR WARRANTY CLAIMS OF ENGINE STALL WHILE DRIVING AT THREE YEARS IN SERVICE IS LOW (LESS THAN 1%).HOWEVER, FURTHER ANALYSIS DETERMINED THAT THE MY 2001 VEHICLE BUILD PERIOD FROM MAY 2000 THROUGH OCTOBER 2000 HAD SIGNIFICANTLY HIGHER (MORE THAN FOUR TIMES) CRANK POSITION FAILURE RATES IN BOTH CONSUMER COMPLAINT DATA AND WARRANTY CLAIM DATA THAN IN THE BUILD PERIOD FROM NOVEMBER 2000 THROUGH JULY 2001.ADDING THE CLAIMS OF KNOWN ENGINE STALL WHILE DRIVING AND CLAIMS WHERE ENGINE STALL WAS INDETERMINATE, THE FAILURE RATE AT THREE YEARS IN SERVICE FOR THIS POPULATION IS OVER 6%.AN ENGINEERING ANALYSIS (EA06-016) HAS BEEN OPENED TO FURTHER ASSESS THE FREQUENCY AND POTENTIAL SAFETY CONSEQUENCES ASSOCIATED WITH THE ALLEGED DEFECT IN VEHICLES BUILT FROM MAY 2000 THROUGH OCTOBER 2000.

Engine And Engine Cooling

THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE06-016) ON MAY 4, 2006 BASED ON ELEVEN VEHICLE OWNER QUESTIONNAIRES (VOQS) AND EARLY WARNING (EWR) DATA ALLEGING SUDDEN ENGINE SHUTDOWN WHILE DRIVING AS A RESULT OF CRANK POSITION SENSOR FAILURES IN MY 2001-2002 GENERAL MOTORS C/K PLATFORM VEHICLES EQUIPPED WITH 8.1L ENGINES.IN RESPONSE TO AN INFORMATION REQUEST LETTER SENT BY ODI, GENERAL MOTORS (GM) PROVIDED OWNER COMPLAINT INFORMATION, FIELD REPORTS AND WARRANTY CLAIM DATA BASED ON A POPULATION OF 108,338 VEHICLES. THE DATA WAS CATEGORIZED BY ENGINE STALLS WHILE DRIVING, ENGINE STALLS WITH AN UNKNOWN DRIVING CONDITION, NO START CONDITIONS AND CLAIMS WHERE IT WAS INDETERMINATE IF AN ENGINE STALL OCCURRED WHILE DRIVING.GENERAL MOTOR'S RESPONSE INCLUDED 1,213 OWNER COMPLAINTS AND FIELD REPORTS OF WHICH 289 WERE CATEGORIZED AS ENGINE STALLS WHILE DRIVING ALLEGEDLY CAUSED BY CRANK POSITION SENSOR FAILURES. GENERAL MOTORS ALSO SUBMITTED WARRANTY CLAIMS FROM ITS REGULAR WARRANTY (5 YEARS/50,000 MILES) AND FROM ITS EXTENDED WARRANTY DATABASE. FROM THE REGULAR WARRANTY DATABASE THERE WERE 3,140 CLAIMS OF CRANK POSITION SENSOR REPLACEMENT OF WHICH 147 CLAIMS WERE FROM CONSUMERS ALLEGING ENGINE STALL WHILE DRIVING.GM STATED THAT 2,841 OF THE CLAIMS WERE INDETERMINATE IF AN ENGINE STALL OCCURRED WHILE DRIVING.FROM ITS EXTENDED WARRANTY DATABASE, GM SUBMITTED 1,561 CLAIMS OF CRANK POSITION SENSOR FAILURE THAT IT ALSO STATED WERE INDETERMINATE AS TO WHETHER AN ENGINE STALL OCCURRED WHILE DRIVING.IN TOTAL, GM REPORTS 4,701 CLAIMS OF CRANK POSITION SENSOR FAILURE COMBINING REGULAR WARRANTY AND EXTENDED WARRANTY.SIMILAR TO GM'S STATISTICAL ANALYSIS, ODI'S ANALYSIS SHOWED THAT THE FAILURE RATE FOR WARRANTY CLAIMS OF ENGINE STALL WHILE DRIVING AT THREE YEARS IN SERVICE IS LOW (LESS THAN 1%).HOWEVER, FURTHER ANALYSIS DETERMINED THAT THE MY 2001 VEHICLE BUILD PERIOD FROM MAY 2000 THROUGH OCTOBER 2000 HAD SIGNIFICANTLY HIGHER (MORE THAN FOUR TIMES) CRANK POSITION FAILURE RATES IN BOTH CONSUMER COMPLAINT DATA AND WARRANTY CLAIM DATA THAN IN THE BUILD PERIOD FROM NOVEMBER 2000 THROUGH JULY 2001.ADDING THE CLAIMS OF KNOWN ENGINE STALL WHILE DRIVING AND CLAIMS WHERE ENGINE STALL WAS INDETERMINATE, THE FAILURE RATE AT THREE YEARS IN SERVICE FOR THIS POPULATION IS OVER 6%.AN ENGINEERING ANALYSIS (EA06-016) HAS BEEN OPENED TO FURTHER ASSESS THE FREQUENCY AND POTENTIAL SAFETY CONSEQUENCES ASSOCIATED WITH THE ALLEGED DEFECT IN VEHICLES BUILT FROM MAY 2000 THROUGH OCTOBER 2000.

DP05009 · Parking Brake Failure

Opened Dec 20, 2005 · Closed May 31, 2006

Status: closed (inferred from source dates) · Parking Brake; Parking Brake:conventional; Parking Brake:conventional:mechanical

ODI'S REVIEW OF COMPLAINT DATA RECEIVED SINCE THE CLOSE OF EA04-011 REVEALED NO INDICATION THAT THE INVESTIGATION SHOULD BE RE-OPENED.MORE DETAILS CAN BE FOUND IN THE FEDERAL REGISTER NOTICE ENCLOSED IN THE DP05-009 PUBLIC FILE.ODI RESERVES THE RIGHT TO REOPEN THE INVESTIGATION IN THE FUTURE SHOULD CONDITIONS WARRANT.

Additional source detail variants (3)

Parking Brake:conventional

ODI'S REVIEW OF COMPLAINT DATA RECEIVED SINCE THE CLOSE OF EA04-011 REVEALED NO INDICATION THAT THE INVESTIGATION SHOULD BE RE-OPENED.MORE DETAILS CAN BE FOUND IN THE FEDERAL REGISTER NOTICE ENCLOSED IN THE DP05-009 PUBLIC FILE.ODI RESERVES THE RIGHT TO REOPEN THE INVESTIGATION IN THE FUTURE SHOULD CONDITIONS WARRANT.

Parking Brake:conventional:mechanical

ODI'S REVIEW OF COMPLAINT DATA RECEIVED SINCE THE CLOSE OF EA04-011 REVEALED NO INDICATION THAT THE INVESTIGATION SHOULD BE RE-OPENED.MORE DETAILS CAN BE FOUND IN THE FEDERAL REGISTER NOTICE ENCLOSED IN THE DP05-009 PUBLIC FILE.ODI RESERVES THE RIGHT TO REOPEN THE INVESTIGATION IN THE FUTURE SHOULD CONDITIONS WARRANT.

Parking Brake

ODI'S REVIEW OF COMPLAINT DATA RECEIVED SINCE THE CLOSE OF EA04-011 REVEALED NO INDICATION THAT THE INVESTIGATION SHOULD BE RE-OPENED.MORE DETAILS CAN BE FOUND IN THE FEDERAL REGISTER NOTICE ENCLOSED IN THE DP05-009 PUBLIC FILE.ODI RESERVES THE RIGHT TO REOPEN THE INVESTIGATION IN THE FUTURE SHOULD CONDITIONS WARRANT.

PE05020 · Unwanted LOW-SPEED Abs Activation

Opened Apr 28, 2005 · Closed Sep 13, 2005

Status: closed (inferred from source dates) · Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip; Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module

IN A LETTER DATED AUGUST 29, 2005, GM NOTIFIED ODI THAT IT WAS RECALLING CERTAIN MODEL YEAR 1999 THROUGH 2002 C/K PICKUP TRUCKS AND SPORT UTILITY VEHICLES TO CORRECT A PROBLEM WITH ANTI-LOCK BRAKE SYSTEM (ABS) WHEEL SPEED SENSOR CORROSION THAT MAY RESULT IN UNWANTED ABS ACTIVATION AND EXTENDED STOPPING DISTANCES DURING LOW-SPEED BRAKING (RECALL 05V-379).GM'S RECALL COVERS APPROXIMATELY 804,000 VEHICLES CURRENTLY REGISTERED IN THE FOLLOWING 14 SALT-BELT STATES:CONNECTICUT, ILLINOIS, INDIANA, MASSACHUSETTS, MAINE, MICHIGAN, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, AND WEST VIRGINIA.THE RECALL PROCEDURE WILL INVOLVE REMOVING THE SENSOR, CLEANING THE MOUNTING SURFACE, APPLYING A RUST INHIBITOR (ZINC-X) TO THE SURFACE, AND REINSTALLING THE SENSOR.IF NECESSARY, THE SENSOR WILL BE REPLACED. THE POPULATION AND FAILURE REPORT DATA GIVEN IN THIS RESUME ARE FOR THE FULL REGION THAT HAS BEEN CONSIDERED BY ODI AS THE SALT-BELT.THAT INCLUDES DELAWARE, IOWA, MARYLAND, MINNESOTA, MISSOURI, WISCONSIN AND THE DISTRICT OF COLUMBIA IN ADDITION TO THE 14 STATES INCLUDED IN 05V-379.THE STATES COVERED BY GM'S RECALL HAVE THE HIGHEST INCIDENT RATES FOR THE SUBJECT CONDITION, ACCOUNTING FOR 91% OF THE INCIDENTS, BUT ONLY 24% OF SUBJECT VEHICLE SALES IN THE UNITED STATES.ODI'S ANALYSIS DETERMINED THAT 840 OF THE COMPLAINTS, 244 OF THE CRASHES, AND 16 OF THE INJURIES IDENTIFIED IN THIS INVESTIGATION OCCURRED IN THOSE STATES.THE RESULTING INCIDENT AND CRASH RATES ARE 96.2 AND 28.0 PER 100,000 VEHICLES RESPECTIVELY (NOTE:RATES ARE BASED ON VEHICLE SALES, NOT REGISTERED VEHICLES). THE CORRESPONDING NUMBERS IN THE EXCLUDED PORTIONS OF THE SALT-BELT ARE 399,000 VEHICLES, 81 INCIDENTS (20.3 PER 100,000 VEHICLES), 3 CRASHES, AND NO INJURIES.THE STATISTICS IN THE REMAINING 30 STATES ARE 2,406,000 VEHICLES, 168 INCIDENTS (7.0 PER 100,000 VEHICLES), 31 CRASHES, AND ONE INJURY.GM AND ODI ARE CONTINUING TO MONITOR THE PROBLEM EXPERIENCE IN STATES THAT ARE NOT INCLUDED IN THE RECALL.GM WILL PROVIDE ODI WITH UPDATED COMPLAINT, FIELD REPORT, AND WARRANTY DATA IN NOVEMBER 2005.ODI AND GM WILL REVIEW THAT DATA AND ASSESS THE APPROPRIATENESS OF THE CURRENT SCOPE OF THE RECALL AT THAT TIME.

Additional source detail variants (2)

Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module

IN A LETTER DATED AUGUST 29, 2005, GM NOTIFIED ODI THAT IT WAS RECALLING CERTAIN MODEL YEAR 1999 THROUGH 2002 C/K PICKUP TRUCKS AND SPORT UTILITY VEHICLES TO CORRECT A PROBLEM WITH ANTI-LOCK BRAKE SYSTEM (ABS) WHEEL SPEED SENSOR CORROSION THAT MAY RESULT IN UNWANTED ABS ACTIVATION AND EXTENDED STOPPING DISTANCES DURING LOW-SPEED BRAKING (RECALL 05V-379).GM'S RECALL COVERS APPROXIMATELY 804,000 VEHICLES CURRENTLY REGISTERED IN THE FOLLOWING 14 SALT-BELT STATES:CONNECTICUT, ILLINOIS, INDIANA, MASSACHUSETTS, MAINE, MICHIGAN, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, AND WEST VIRGINIA.THE RECALL PROCEDURE WILL INVOLVE REMOVING THE SENSOR, CLEANING THE MOUNTING SURFACE, APPLYING A RUST INHIBITOR (ZINC-X) TO THE SURFACE, AND REINSTALLING THE SENSOR.IF NECESSARY, THE SENSOR WILL BE REPLACED. THE POPULATION AND FAILURE REPORT DATA GIVEN IN THIS RESUME ARE FOR THE FULL REGION THAT HAS BEEN CONSIDERED BY ODI AS THE SALT-BELT.THAT INCLUDES DELAWARE, IOWA, MARYLAND, MINNESOTA, MISSOURI, WISCONSIN AND THE DISTRICT OF COLUMBIA IN ADDITION TO THE 14 STATES INCLUDED IN 05V-379.THE STATES COVERED BY GM'S RECALL HAVE THE HIGHEST INCIDENT RATES FOR THE SUBJECT CONDITION, ACCOUNTING FOR 91% OF THE INCIDENTS, BUT ONLY 24% OF SUBJECT VEHICLE SALES IN THE UNITED STATES.ODI'S ANALYSIS DETERMINED THAT 840 OF THE COMPLAINTS, 244 OF THE CRASHES, AND 16 OF THE INJURIES IDENTIFIED IN THIS INVESTIGATION OCCURRED IN THOSE STATES.THE RESULTING INCIDENT AND CRASH RATES ARE 96.2 AND 28.0 PER 100,000 VEHICLES RESPECTIVELY (NOTE:RATES ARE BASED ON VEHICLE SALES, NOT REGISTERED VEHICLES). THE CORRESPONDING NUMBERS IN THE EXCLUDED PORTIONS OF THE SALT-BELT ARE 399,000 VEHICLES, 81 INCIDENTS (20.3 PER 100,000 VEHICLES), 3 CRASHES, AND NO INJURIES.THE STATISTICS IN THE REMAINING 30 STATES ARE 2,406,000 VEHICLES, 168 INCIDENTS (7.0 PER 100,000 VEHICLES), 31 CRASHES, AND ONE INJURY.GM AND ODI ARE CONTINUING TO MONITOR THE PROBLEM EXPERIENCE IN STATES THAT ARE NOT INCLUDED IN THE RECALL.GM WILL PROVIDE ODI WITH UPDATED COMPLAINT, FIELD REPORT, AND WARRANTY DATA IN NOVEMBER 2005.ODI AND GM WILL REVIEW THAT DATA AND ASSESS THE APPROPRIATENESS OF THE CURRENT SCOPE OF THE RECALL AT THAT TIME.

Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip

IN A LETTER DATED AUGUST 29, 2005, GM NOTIFIED ODI THAT IT WAS RECALLING CERTAIN MODEL YEAR 1999 THROUGH 2002 C/K PICKUP TRUCKS AND SPORT UTILITY VEHICLES TO CORRECT A PROBLEM WITH ANTI-LOCK BRAKE SYSTEM (ABS) WHEEL SPEED SENSOR CORROSION THAT MAY RESULT IN UNWANTED ABS ACTIVATION AND EXTENDED STOPPING DISTANCES DURING LOW-SPEED BRAKING (RECALL 05V-379).GM'S RECALL COVERS APPROXIMATELY 804,000 VEHICLES CURRENTLY REGISTERED IN THE FOLLOWING 14 SALT-BELT STATES:CONNECTICUT, ILLINOIS, INDIANA, MASSACHUSETTS, MAINE, MICHIGAN, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, AND WEST VIRGINIA.THE RECALL PROCEDURE WILL INVOLVE REMOVING THE SENSOR, CLEANING THE MOUNTING SURFACE, APPLYING A RUST INHIBITOR (ZINC-X) TO THE SURFACE, AND REINSTALLING THE SENSOR.IF NECESSARY, THE SENSOR WILL BE REPLACED. THE POPULATION AND FAILURE REPORT DATA GIVEN IN THIS RESUME ARE FOR THE FULL REGION THAT HAS BEEN CONSIDERED BY ODI AS THE SALT-BELT.THAT INCLUDES DELAWARE, IOWA, MARYLAND, MINNESOTA, MISSOURI, WISCONSIN AND THE DISTRICT OF COLUMBIA IN ADDITION TO THE 14 STATES INCLUDED IN 05V-379.THE STATES COVERED BY GM'S RECALL HAVE THE HIGHEST INCIDENT RATES FOR THE SUBJECT CONDITION, ACCOUNTING FOR 91% OF THE INCIDENTS, BUT ONLY 24% OF SUBJECT VEHICLE SALES IN THE UNITED STATES.ODI'S ANALYSIS DETERMINED THAT 840 OF THE COMPLAINTS, 244 OF THE CRASHES, AND 16 OF THE INJURIES IDENTIFIED IN THIS INVESTIGATION OCCURRED IN THOSE STATES.THE RESULTING INCIDENT AND CRASH RATES ARE 96.2 AND 28.0 PER 100,000 VEHICLES RESPECTIVELY (NOTE:RATES ARE BASED ON VEHICLE SALES, NOT REGISTERED VEHICLES). THE CORRESPONDING NUMBERS IN THE EXCLUDED PORTIONS OF THE SALT-BELT ARE 399,000 VEHICLES, 81 INCIDENTS (20.3 PER 100,000 VEHICLES), 3 CRASHES, AND NO INJURIES.THE STATISTICS IN THE REMAINING 30 STATES ARE 2,406,000 VEHICLES, 168 INCIDENTS (7.0 PER 100,000 VEHICLES), 31 CRASHES, AND ONE INJURY.GM AND ODI ARE CONTINUING TO MONITOR THE PROBLEM EXPERIENCE IN STATES THAT ARE NOT INCLUDED IN THE RECALL.GM WILL PROVIDE ODI WITH UPDATED COMPLAINT, FIELD REPORT, AND WARRANTY DATA IN NOVEMBER 2005.ODI AND GM WILL REVIEW THAT DATA AND ASSESS THE APPROPRIATENESS OF THE CURRENT SCOPE OF THE RECALL AT THAT TIME.

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.

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.

EA04005 · Tailgate Cable Breakage

Opened Feb 19, 2004 · Closed Sep 28, 2004

Status: closed (inferred from source dates) · Latches/locks/linkages:tailgate:latch; Structure:body:tailgate ; Structure:body:tailgate:hinge And Attachments

GENERAL MOTORS FILED A DEFECT NOTICE 04V-129 ON MARCH 17, 2004, WHICH OUTLINES A PROGRAM TO REPLACE THE TAILGATE CABLES INSTALLED IN AFFECTED MODEL YEAR 2000-2004 VEHICLES.REFER TO ODI'S CLOSING REPORT FOR EA04-005 FOR ADDITIONAL INFORMATION.ODI IS AWARE OF REPORTS OF TAILGATE CABLE BREAKAGE OCCURRING IN MODEL YEAR 1999 AND EARLIER VEHICLES.THESE VEHICLES WERE EQUIPPED WITH SIMILAR TAILGATE CABLES AS ADDRESSED BY 04V-129, BUT ARE NOT BEING ADDRESSED BY CAMPAIGN O4V-129.ODI IS INITIATING A SEPARATE INVESTIGATION TO ADDRESS THESE VEHICLES.THE COMPLAINT-INJURY-FATALITY STATISTICS SUMMARIZED ABOVE PERTAIN TO MODEL YEAR 2000-2004 VEHICLES. THE COMPLAINT-INJURY STATISTICS FOR MODEL YEAR 1999 AND EARLIER VEHICLES ARE SUMMARIZED ON THE OPENING RESUME FOR THAT INVESTIGATION.

Additional source detail variants (6)

Latches/locks/linkages:tailgate:latch

GENERAL MOTORS FILED A DEFECT NOTICE 04V-129 ON MARCH 17, 2004, WHICH OUTLINES A PROGRAM TO REPLACE THE TAILGATE CABLES INSTALLED IN AFFECTED MODEL YEAR 2000-2004 VEHICLES.REFER TO ODI'S CLOSING REPORT FOR EA04-005 FOR ADDITIONAL INFORMATION.ODI IS AWARE OF REPORTS OF TAILGATE CABLE BREAKAGE OCCURRING IN MODEL YEAR 1999 AND EARLIER VEHICLES.THESE VEHICLES WERE EQUIPPED WITH SIMILAR TAILGATE CABLES AS ADDRESSED BY 04V-129, BUT ARE NOT BEING ADDRESSED BY CAMPAIGN O4V-129.ODI IS INITIATING A SEPARATE INVESTIGATION TO ADDRESS THESE VEHICLES.THE COMPLAINT-INJURY-FATALITY STATISTICS SUMMARIZED ABOVE PERTAIN TO MODEL YEAR 2000-2004 VEHICLES. THE COMPLAINT-INJURY STATISTICS FOR MODEL YEAR 1999 AND EARLIER VEHICLES ARE SUMMARIZED ON THE OPENING RESUME FOR THAT INVESTIGATION.

Latches/locks/linkages:tailgate:latch

GENERAL MOTORS FILED A DEFECT NOTICE 04V-129 ON MARCH 17, 2004, WHICH OUTLINES A PROGRAM TO REPLACE THE TAILGATE CABLES INSTALLED IN AFFECTED MODEL YEAR 2000-2004 VEHICLES.REFER TO ODI'S CLOSING REPORT FOR EA04-005 FOR ADDITIONAL INFORMATION.ODI IS AWARE OF REPORTS OF TAILGATE CABLE BREAKAGE OCCURRING IN MODEL YEAR 1999 AND EARLIER VEHICLES.THESE VEHICLES WERE EQUIPPED WITH SIMILAR TAILGATE CABLES AS ADDRESSED BY 04V-129, BUT ARE NOT BEING ADDRESSED BY CAMPAIGN O4V-129.ODI IS INITIATING A SEPARATE INVESTIGATION TO ADDRESS THESE VEHICLES.THE COMPLAINT-INJURY-FATALITY STATISTICS SUMMARIZED ABOVE PERTAIN TO MODEL YEAR 2000-2004 VEHICLES. THE COMPLAINT-INJURY STATISTICS FOR MODEL YEAR 1999 AND EARLIER VEHICLES ARE SUMMARIZED ON THE OPENING RESUME FOR THAT INVESTIGATION.

Structure:body:tailgate

GENERAL MOTORS FILED A DEFECT NOTICE 04V-129 ON MARCH 17, 2004, WHICH OUTLINES A PROGRAM TO REPLACE THE TAILGATE CABLES INSTALLED IN AFFECTED MODEL YEAR 2000-2004 VEHICLES.REFER TO ODI'S CLOSING REPORT FOR EA04-005 FOR ADDITIONAL INFORMATION.ODI IS AWARE OF REPORTS OF TAILGATE CABLE BREAKAGE OCCURRING IN MODEL YEAR 1999 AND EARLIER VEHICLES.THESE VEHICLES WERE EQUIPPED WITH SIMILAR TAILGATE CABLES AS ADDRESSED BY 04V-129, BUT ARE NOT BEING ADDRESSED BY CAMPAIGN O4V-129.ODI IS INITIATING A SEPARATE INVESTIGATION TO ADDRESS THESE VEHICLES.THE COMPLAINT-INJURY-FATALITY STATISTICS SUMMARIZED ABOVE PERTAIN TO MODEL YEAR 2000-2004 VEHICLES. THE COMPLAINT-INJURY STATISTICS FOR MODEL YEAR 1999 AND EARLIER VEHICLES ARE SUMMARIZED ON THE OPENING RESUME FOR THAT INVESTIGATION.

Structure:body:tailgate

GENERAL MOTORS FILED A DEFECT NOTICE 04V-129 ON MARCH 17, 2004, WHICH OUTLINES A PROGRAM TO REPLACE THE TAILGATE CABLES INSTALLED IN AFFECTED MODEL YEAR 2000-2004 VEHICLES.REFER TO ODI'S CLOSING REPORT FOR EA04-005 FOR ADDITIONAL INFORMATION.ODI IS AWARE OF REPORTS OF TAILGATE CABLE BREAKAGE OCCURRING IN MODEL YEAR 1999 AND EARLIER VEHICLES.THESE VEHICLES WERE EQUIPPED WITH SIMILAR TAILGATE CABLES AS ADDRESSED BY 04V-129, BUT ARE NOT BEING ADDRESSED BY CAMPAIGN O4V-129.ODI IS INITIATING A SEPARATE INVESTIGATION TO ADDRESS THESE VEHICLES.THE COMPLAINT-INJURY-FATALITY STATISTICS SUMMARIZED ABOVE PERTAIN TO MODEL YEAR 2000-2004 VEHICLES. THE COMPLAINT-INJURY STATISTICS FOR MODEL YEAR 1999 AND EARLIER VEHICLES ARE SUMMARIZED ON THE OPENING RESUME FOR THAT INVESTIGATION.

Structure:body:tailgate:hinge And Attachments

GENERAL MOTORS FILED A DEFECT NOTICE 04V-129 ON MARCH 17, 2004, WHICH OUTLINES A PROGRAM TO REPLACE THE TAILGATE CABLES INSTALLED IN AFFECTED MODEL YEAR 2000-2004 VEHICLES.REFER TO ODI'S CLOSING REPORT FOR EA04-005 FOR ADDITIONAL INFORMATION.ODI IS AWARE OF REPORTS OF TAILGATE CABLE BREAKAGE OCCURRING IN MODEL YEAR 1999 AND EARLIER VEHICLES.THESE VEHICLES WERE EQUIPPED WITH SIMILAR TAILGATE CABLES AS ADDRESSED BY 04V-129, BUT ARE NOT BEING ADDRESSED BY CAMPAIGN O4V-129.ODI IS INITIATING A SEPARATE INVESTIGATION TO ADDRESS THESE VEHICLES.THE COMPLAINT-INJURY-FATALITY STATISTICS SUMMARIZED ABOVE PERTAIN TO MODEL YEAR 2000-2004 VEHICLES. THE COMPLAINT-INJURY STATISTICS FOR MODEL YEAR 1999 AND EARLIER VEHICLES ARE SUMMARIZED ON THE OPENING RESUME FOR THAT INVESTIGATION.

Structure:body:tailgate:hinge And Attachments

GENERAL MOTORS FILED A DEFECT NOTICE 04V-129 ON MARCH 17, 2004, WHICH OUTLINES A PROGRAM TO REPLACE THE TAILGATE CABLES INSTALLED IN AFFECTED MODEL YEAR 2000-2004 VEHICLES.REFER TO ODI'S CLOSING REPORT FOR EA04-005 FOR ADDITIONAL INFORMATION.ODI IS AWARE OF REPORTS OF TAILGATE CABLE BREAKAGE OCCURRING IN MODEL YEAR 1999 AND EARLIER VEHICLES.THESE VEHICLES WERE EQUIPPED WITH SIMILAR TAILGATE CABLES AS ADDRESSED BY 04V-129, BUT ARE NOT BEING ADDRESSED BY CAMPAIGN O4V-129.ODI IS INITIATING A SEPARATE INVESTIGATION TO ADDRESS THESE VEHICLES.THE COMPLAINT-INJURY-FATALITY STATISTICS SUMMARIZED ABOVE PERTAIN TO MODEL YEAR 2000-2004 VEHICLES. THE COMPLAINT-INJURY STATISTICS FOR MODEL YEAR 1999 AND EARLIER VEHICLES ARE SUMMARIZED ON THE OPENING RESUME FOR THAT INVESTIGATION.

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.

PE03049 · Tailgate Cable Breakage

Opened Oct 23, 2003 · Closed Feb 19, 2004

Status: closed (inferred from source dates) · Latches/locks/linkages:tailgate:latch

DURING THE PE, ODIDISCOVERED THAT ONE OR BOTH OF THE TAILGATE SUPPORT CABLES CAN BREAK DUE TO THE EFFECTS OF METAL FATIGUE AT THE POINT WHERE THE CABLE FLEXES WHEN THE LIFT GATE IS OPENED AND CLOSED. CONCURRENTLY, THE STRENGTH OF THE CABLE DEGRADES OVER TIME DUE TO CORROSION OF THE WIRE STRANDS IN THE SUPPORT CABLES.WHEN THE VEHICLE IS STATIONARY AND CARGO IS BEING LOADED OR UNLOADED, THE TAILGATE CAN TIP DOWNWARD DISPLACING CARGO AND/OR PEOPLE TO THE GROUND WITHOUT WARNING.ODI IS ALSO AWARE OF ONE TOTAL SEPARATION OF THE TAILGATE FROM THE VEHICLE.OWNERS CANNOT EASILY DETECT WHETHER THE SUPPORT CABES ARE DAMAGED OR CORRODED BECAUSE THEY ARE COVERED BY A PROTECTIVE SHEATH.ODI IS UPGRADING THIS PRELIMINARY EVALUATION FOR FURTHER APPROPRIATE ACTION.MODEL YEAR 2003 VEHICLES WILL BE ADDED TO THE INVESTIGATION.FURTHER, WE WILL INCUDE ADDITIONAL VEHICLES, THOSE BEING THE AVALANCHE AND CADILLAC EXT, MODEL YEARS 2002-2003, AND THE SIERRA, MODEL YEARS 1999-2003.

PE03026 · Steel Wheel Rim Fracture

Opened Jun 12, 2003 · Closed Nov 3, 2003

Status: closed (inferred from source dates) · Wheels; Wheels:multi Piece; Wheels:rim

THERE HAVE BEEN LESS THAN 2 COMPLAINTS PER 100,000 SUBJECT VEHICLES RELATED TO THE ALLEGED DEFECT.THE OLDEST VEHICLES (MY 1999) HAVE ONLY 2 COMPLAINTS IN OVER 140 THOUSAND VEHICLES AFTER OVER 4 YEARS IN SERVICE.THE RATE OF WARRANTY CLAIMS POTENTIALLY RELATED TO THE ALLEGED DEFECT IS LESS THAN 0.1%.THERE ARE NO KNOWN INCIDENTS INVOLVING RAPID LOSS OF TIRE PRESSURE OR LOSS OF VEHICLE CONTROL. A DEFECT TREND 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 NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.

Additional source detail variants (3)

Wheels

THERE HAVE BEEN LESS THAN 2 COMPLAINTS PER 100,000 SUBJECT VEHICLES RELATED TO THE ALLEGED DEFECT.THE OLDEST VEHICLES (MY 1999) HAVE ONLY 2 COMPLAINTS IN OVER 140 THOUSAND VEHICLES AFTER OVER 4 YEARS IN SERVICE.THE RATE OF WARRANTY CLAIMS POTENTIALLY RELATED TO THE ALLEGED DEFECT IS LESS THAN 0.1%.THERE ARE NO KNOWN INCIDENTS INVOLVING RAPID LOSS OF TIRE PRESSURE OR LOSS OF VEHICLE CONTROL. A DEFECT TREND 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 NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.

Wheels:multi Piece

THERE HAVE BEEN LESS THAN 2 COMPLAINTS PER 100,000 SUBJECT VEHICLES RELATED TO THE ALLEGED DEFECT.THE OLDEST VEHICLES (MY 1999) HAVE ONLY 2 COMPLAINTS IN OVER 140 THOUSAND VEHICLES AFTER OVER 4 YEARS IN SERVICE.THE RATE OF WARRANTY CLAIMS POTENTIALLY RELATED TO THE ALLEGED DEFECT IS LESS THAN 0.1%.THERE ARE NO KNOWN INCIDENTS INVOLVING RAPID LOSS OF TIRE PRESSURE OR LOSS OF VEHICLE CONTROL. A DEFECT TREND 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 NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.

Wheels:rim

THERE HAVE BEEN LESS THAN 2 COMPLAINTS PER 100,000 SUBJECT VEHICLES RELATED TO THE ALLEGED DEFECT.THE OLDEST VEHICLES (MY 1999) HAVE ONLY 2 COMPLAINTS IN OVER 140 THOUSAND VEHICLES AFTER OVER 4 YEARS IN SERVICE.THE RATE OF WARRANTY CLAIMS POTENTIALLY RELATED TO THE ALLEGED DEFECT IS LESS THAN 0.1%.THERE ARE NO KNOWN INCIDENTS INVOLVING RAPID LOSS OF TIRE PRESSURE OR LOSS OF VEHICLE CONTROL. A DEFECT TREND 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 NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.

EA02015 · Throttle Sticking Closed

Opened Aug 1, 2002 · Closed Jan 12, 2004

Status: closed (inferred from source dates) · Vehicle Speed Control:linkages

THIS INVESTIGATION INVOLVES THE GENERAL MOTORS CORPORATION (GM)THROTTLE BODY (TB) UTILIZED IN MODEL YEAR (MY) 1999-2002 SILVERADO, SIERRA, TAHOE, SUBURBAN, AVALANCHE AND YUKON (SUBJECT VEHICLE(S)) WITH 4.8L, 5.3L, AND 6.0L ENGINES. THE TB VALVE MAY INTERMITTENTLY STICK IN A CLOSED POSITION.IN SUCH A SITUATION, AN OPERATOR MAY APPLY ADDITIONAL ACCELERATOR PEDAL FORCE TO INCREASE ENGINE SPEED.THE APPLICATION OF ADDITIONAL ACCELERATOR PEDAL FORCE, TO OPEN A STUCK THROTTLE VALVE, MAY OPEN THE THROTTLE VALVE MORE THAN INTENDED AND, IN TURN, ACCELERATE THE ENGINE AND VEHICLE MORE THAN INTENDED AND REASONABLY EXPECTED BY THE DRIVER.ON AUGUST 1, 2002, THE OFFICE OF DEFECTS INVESTIGATION (ODI), OF THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION (NHTSA), OPENED THIS ENGINEERING ANALYSIS.THE INVESTIGATION REVEALED THAT TWO FACTORS MAY CAUSE THE DEFECT: 1) TB MANUFACTURING PROCESS PROBLEMS; AND 2) ACCUMULATION OF DEPOSITS (A PCV SYSTEM BY-PRODUCT) ON OR AROUND THE TB THROTTLE VALVE AND BORE.ODI CONCLUDES THAT THE TB PERFORMS IN A DEFECTIVE MANNER AFTER ANALYZING GM?S DATA SUBMISSIONS, AND TEST DATA COLLECTED BY THE VEHICLE RESEARCH AND TEST CENTER (VRTC).FIFTY-NINE CRASHES ARE ALLEGED TO HAVE OCCURRED AS A RESULT OF GM?S TB DEFECT.THE MAJORITY OF THE CRASHES INVOLVE A SINGLE VEHICLE, ENGAGING IN A CLOSE QUARTER VEHICLE MANEUVER (OR LOW SPEED), AND CAUSING ONLY MINOR PROPERTY DAMAGE.FOUR OUT OF THE FIFTY-NINE CRASHES INVOLVE INJURY, AND THOSE INJURIES WERE MINOR.ALTHOUGH GM?S TB IS DEFECTIVE, BASED ON THE EVIDENCE GATHERED, ODI HAS FOUND THAT THE ACCELERATOR PEDAL FORCE REQUIRED TO OPEN A STUCK THROTTLE VALVE IS NEGLIGIBLE, AND THE THROTTLE VALVE DOES NOT STICK IN THE OPEN POSITION.THEREFORE THIS ENGINEERING ANALYSIS (EA02-015) WILL BE CLOSED AT THIS TIME.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.FOR A DETAILED DISCUSSION OF THE TB COMPONENT AND TESTING, PLEASE SEE THE ATTACHED REPORT.

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