NHTSA owner reports · September 18, 2026 snapshot.
Service Brakes, Hydraulic complaints
24 reportsClear category filter109,065 miles · May 27, 2011
Service Brakes, Hydraulic
THE METAL BRAKE LINES ON MY 03 CHEVY AVALANCHE 1500 Z1 TRUCK ARE CATASTROPHICALLY FAILING. THERE IS NO WARNING PRIOR AS THERE WOULD BE WITH OTHER BRAKE RELATED PROBLEMS. THIS FAILURE LEADS TO AN INABILITY TO STOP THE VEHICLE, THE RESULT OF WHICH COULD BE DEADLY. THE DEGRADATION OF THE STEEL LINES IS SO BAD THAT REPLACEMENT OF AL…
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THE METAL BRAKE LINES ON MY 03 CHEVY AVALANCHE 1500 Z1 TRUCK ARE CATASTROPHICALLY FAILING. THERE IS NO WARNING PRIOR AS THERE WOULD BE WITH OTHER BRAKE RELATED PROBLEMS. THIS FAILURE LEADS TO AN INABILITY TO STOP THE VEHICLE, THE RESULT OF WHICH COULD BE DEADLY. THE DEGRADATION OF THE STEEL LINES IS SO BAD THAT REPLACEMENT OF ALL LINE ARE REQUIRED. *TR
NHTSA ODI #10402928
142,000 miles · Apr 4, 2011
Service Brakes, Hydraulic
I CHANGED THE FRONT BRAKES AND WAS ADJUSTING THEM WHEN THE REAR BRAKE LINE STARTED GUSHING OUT BRAKE FLUID. IHAD IT TOWED TO A MECHANIC AND EXPLAINED WHAT HAD HAPPENED AND BEFORE I FINISHED HE SAID LET ME GUESS "YOU BLED THE FRONT BRAKES AND BLEW OUT THE BACK LINE NEXT TO THE GAS TANK BE HIND THE REAR DRIVER SIDE WHEEL." THIS …
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I CHANGED THE FRONT BRAKES AND WAS ADJUSTING THEM WHEN THE REAR BRAKE LINE STARTED GUSHING OUT BRAKE FLUID. IHAD IT TOWED TO A MECHANIC AND EXPLAINED WHAT HAD HAPPENED AND BEFORE I FINISHED HE SAID LET ME GUESS "YOU BLED THE FRONT BRAKES AND BLEW OUT THE BACK LINE NEXT TO THE GAS TANK BE HIND THE REAR DRIVER SIDE WHEEL." THIS EXACTLY WHAT HAPPENED HE SAID ALOT OF CHEVY TRUCKS HAVE THE SAME PROBLEM. HE IS GOING TTO CHANGE THE REAR LINE. HE SAID WHERE THE LINE IS MOUNTED ALLOWS GRIT SALT AND THINGS BUILD UP IN THIS SPOTCAUSING THE BRAKE LINE TO RUST INTO. THIS COULD HAVE GOTTEN US KILLED HAD I NEEDED TO HIT MY BRAKES HARD. *TR
NHTSA ODI #10394246
85,000 miles · Oct 8, 2010
Service Brakes, HydraulicCrash
TL* THE CONTACT OWNS A 2003 GMC 1500 AVALANCHE. THE CONTACT WAS DRIVING APPROXIMATELY 20 MPH AND THE BRAKES FAILED TO RESPOND UPON ENGAGEMENT. THE VEHICLE CRASHED INTO SIX DIFFERENT VEHICLES. THERE WERE NO PERSONAL INJURIES. A POLICE REPORT WAS FILED FOR THE INCIDENT. THE VEHICLE SUSTAINED MINOR DAMAGE AND WAS TOWED TO AN INDEPE…
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TL* THE CONTACT OWNS A 2003 GMC 1500 AVALANCHE. THE CONTACT WAS DRIVING APPROXIMATELY 20 MPH AND THE BRAKES FAILED TO RESPOND UPON ENGAGEMENT. THE VEHICLE CRASHED INTO SIX DIFFERENT VEHICLES. THERE WERE NO PERSONAL INJURIES. A POLICE REPORT WAS FILED FOR THE INCIDENT. THE VEHICLE SUSTAINED MINOR DAMAGE AND WAS TOWED TO AN INDEPENDENT MECHANIC WHERE IT WAS DISCOVERED THAT THE BRAKE LINES FRACTURED DUE TO CORROSION. THE BRAKE LINE TUBING WAS REPLACED. THE FAILURE MILEAGE WAS 85,000.
NHTSA ODI #10359667
115,000 miles · Sep 1, 2010
Service Brakes, Hydraulic
RUSTED BRAKE LINE TO REAR BRAKES FAILED. REDUCED BRAKING ABILITY PREVENTED VEHICLE FROM STOPPING ALLOWING VEHICLE TO PASS INTO AN INTERSECTION. ALL RUSTED BRAKE LINES REAR AND FRONT HAD TO BE REPLACED. OLD PARTS MAY STILL BE AVAILABLE. *TR
NHTSA ODI #10353413
86,029 miles · Aug 24, 2010
Service Brakes, Hydraulic
RUSTED OUT 2003 CHEVY AVALANCHE BRAKE LINE LEADING TO BRAKE FAILURE. *TR
NHTSA ODI #10351585
81,000 miles · Aug 21, 2010
Service Brakes, Hydraulic
2003 CHEVY AVALANCHE HAD CATASTROPHIC BRAKE FAILURE WHILE BEING DRIVEN. UPON INSPECTION FOUND SEVERELY CORRODED BRAKE LINES DRIVER SIDE ABOVE CHASSIS RAIL. *TR
NHTSA ODI #10351060
145,672 miles · Jul 14, 2010
Service Brakes, Hydraulic
APROACHING A STOP SIGN BEHIND ANOTHER VEHICALE AT ABOUT 50 MPH WHEN APPLYING THE BRAKES I FELT A POP AND THE PEDAL WENT TO THE FLOOR. THE BRAKES HAD COMPLETELY FAILED. USING THE PARKINNG BRAKE AND DOWN SHIFTING BROUGHT THE VEHICLE TO A STOP BEFORE I HIT THE VEHICLE IN FRONT. IT IS AN AUTOMETIC. AT THE END I HAD IT IN 1ST GEAR AN…
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APROACHING A STOP SIGN BEHIND ANOTHER VEHICALE AT ABOUT 50 MPH WHEN APPLYING THE BRAKES I FELT A POP AND THE PEDAL WENT TO THE FLOOR. THE BRAKES HAD COMPLETELY FAILED. USING THE PARKINNG BRAKE AND DOWN SHIFTING BROUGHT THE VEHICLE TO A STOP BEFORE I HIT THE VEHICLE IN FRONT. IT IS AN AUTOMETIC. AT THE END I HAD IT IN 1ST GEAR AND TURNED OFF THE IGNITION FOR THE STOP. IT IS A 2003 AVALANCH VIN# [XXX]. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
NHTSA ODI #10343163
Mileage unknown · May 5, 2010
Service Brakes, Hydraulic
WEAK BRAKES, LONG STOPPING DISTANCE, NO WEAR ON FRONT PADS, FRONT PADS STUCK, TAKEN TO DEALER 3 TIMES AND THEY SAY NOTHING IS WRONG, I BELIEVE I WOULD NOT BE ABLE TO STOP IN TIME UNDER EMERGENCY CONDITIONS. THE BACK BRAKES HAVE BEEN CHANGED 3 TIMES (WORE TO WEAR INDICATOR) AND THE FRONTS PADS AND ROTORS LOOK NEW (GLAZED OVER NO…
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WEAK BRAKES, LONG STOPPING DISTANCE, NO WEAR ON FRONT PADS, FRONT PADS STUCK, TAKEN TO DEALER 3 TIMES AND THEY SAY NOTHING IS WRONG, I BELIEVE I WOULD NOT BE ABLE TO STOP IN TIME UNDER EMERGENCY CONDITIONS. THE BACK BRAKES HAVE BEEN CHANGED 3 TIMES (WORE TO WEAR INDICATOR) AND THE FRONTS PADS AND ROTORS LOOK NEW (GLAZED OVER NO FRICTION) THIS HAS BEEN ONGOING SINCE BUYING TRUCK BRAND NEW IN 2003. *TR
NHTSA ODI #10329064
Mileage unknown · Apr 12, 2010
Service Brakes, Hydraulic
TL*THE CONTACT OWNS A 2003 CHEVROLET AVALANCHE 1500. THE CONTACT WAS DRIVING APPROXIMATELY 45 MPH WITH THE BRAKES DEPRESSED WHEN THE ANTILOCK BRAKE SYSTEM ACTIVATED. THE BRAKES BECAME EXTREMELY SPONGY WHICH MADE IT DIFFICULT TO STOP THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER WHO STATED THAT THE BRAKES FUNCTIONED NORMALLY. …
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TL*THE CONTACT OWNS A 2003 CHEVROLET AVALANCHE 1500. THE CONTACT WAS DRIVING APPROXIMATELY 45 MPH WITH THE BRAKES DEPRESSED WHEN THE ANTILOCK BRAKE SYSTEM ACTIVATED. THE BRAKES BECAME EXTREMELY SPONGY WHICH MADE IT DIFFICULT TO STOP THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER WHO STATED THAT THE BRAKES FUNCTIONED NORMALLY. THE FAILURE MILEAGE WAS UNKNOWN. THE CURRENT MILEAGE WAS 51,000.
NHTSA ODI #10325070
49,000 miles · Aug 12, 2009
Service Brakes, Hydraulic
SAME PROBLEM AS FOUND IN NHTSA ID # 05V37900 IN 2002 CHEVY AVALANCHE IS OCCURRING IN MY 2003 CHEVY AVALANCHE. THE ABS IS ACTIVATED WHEN REACHING A SPEED OF 5 MPH OR LESS. THIS IS CAUSING MY AVALANCHE TO NOT STOP IMMEDIATELY AT STOP SIGNS OR RED LIGHTS. MY AVALANCHE WILL TRAVEL APPROXIMATELY 2 TO 3 FEET CLOSER TO THE CAR OR IN…
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SAME PROBLEM AS FOUND IN NHTSA ID # 05V37900 IN 2002 CHEVY AVALANCHE IS OCCURRING IN MY 2003 CHEVY AVALANCHE. THE ABS IS ACTIVATED WHEN REACHING A SPEED OF 5 MPH OR LESS. THIS IS CAUSING MY AVALANCHE TO NOT STOP IMMEDIATELY AT STOP SIGNS OR RED LIGHTS. MY AVALANCHE WILL TRAVEL APPROXIMATELY 2 TO 3 FEET CLOSER TO THE CAR OR INTERSECTION I AM STOPPING AT. IF I ROLL THROUGH THE STOP SIGN OR NOT GO BELOW 5 MPH WHILE TURNING, THE ABS DO NOT COME ON. *TR
NHTSA ODI #10280174
NHTSA investigations
1EA11001 · 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
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