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2003 Chevrolet Silverado 1500

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2003 Chevrolet Silverado 1500 do not stand out strongly from the model-year median of 525.

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When problems were reported

Mileage at the reported incident

726 reports with mileage · 79 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. Review the 273 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 195 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes, Hydraulic. Review the 151 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

26 crash reports7 fire reports8 injury reports

Service Brakes complaints

273 reports
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121,000 miles · Feb 20, 2014
Service Brakes

WENT TO PARK MY TRUCK AND THE BRAKE PEDAL WENT TO THE FLOOR, TRIED TO PUMP THE PEDAL BUT IT STILL WENT TO THE FLOOR. SHUT THE TRUCK OFF AND LOOKED AT THE UNDER SIDE AND SEEN BRAKE FLUID RUNNING OUT OF A BRAKE LINE. AND I LOOKED A LITTLE CLOSER AND SEEN THAT MOST OF THE BRAKE LINE UNDER THE TRUCK WERE RUSTED VERY BAD. HAD TO HAV…

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WENT TO PARK MY TRUCK AND THE BRAKE PEDAL WENT TO THE FLOOR, TRIED TO PUMP THE PEDAL BUT IT STILL WENT TO THE FLOOR. SHUT THE TRUCK OFF AND LOOKED AT THE UNDER SIDE AND SEEN BRAKE FLUID RUNNING OUT OF A BRAKE LINE. AND I LOOKED A LITTLE CLOSER AND SEEN THAT MOST OF THE BRAKE LINE UNDER THE TRUCK WERE RUSTED VERY BAD. HAD TO HAVE MY TRUCK TOWED TO THE SHOP TO BE FIXED. THEY SAID THAT ALL MY BRAKE LINE MUST BE REPLACED OR I COULD HAVE A BAD WRECK. AND THE PRICE. NOT GOOD. *TR

NHTSA ODI #10565146

88,652 miles · Feb 15, 2014
Service Brakes

UPON LEAVING MY HOUSE IN SAID TRUCK YESTERDAY, 12/14/2014, FORTUNATELY I WAS STILL WITHIN MY SUBDIVISION, I EXPERIENCED TOTAL BRAKE FAILURE, WITH THE PEDAL GOING ALL THE WAY TO THE FLOOR. THE ONLY THING THAT STOPPED THE TRUCK WAS A SNOW BANK. THE SERVICE BRAKE SYSTEM MESSAGE DISPLAYED AT THE SAME TIME. THERE WAS NO PRIOR INDICAT…

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UPON LEAVING MY HOUSE IN SAID TRUCK YESTERDAY, 12/14/2014, FORTUNATELY I WAS STILL WITHIN MY SUBDIVISION, I EXPERIENCED TOTAL BRAKE FAILURE, WITH THE PEDAL GOING ALL THE WAY TO THE FLOOR. THE ONLY THING THAT STOPPED THE TRUCK WAS A SNOW BANK. THE SERVICE BRAKE SYSTEM MESSAGE DISPLAYED AT THE SAME TIME. THERE WAS NO PRIOR INDICATION OR WARNING THAT MY BRAKES WERE GETTING READY TO FAIL. I WAS ABLE TO GET THE TRUCK BACK INTO MY DRIVE WAY USING THE EMERGENCY BRAKE AND CALLED AAA. THERE WAS BRAKE FLUID EVERYWHERE UNDER THE TRUCK. THEY TOWED MY TRUCK TO AAA CARE IN FREDERICKSBURG, VA WHERE THEY DISCOVERED THE HOLE IN THE LINE DUE TO RUST. THEY REPLACED THE LINE FROM THE LF WHEEL TO THE ABS PUMP WITH TOTAL REPAIRS COMING TO $415. THEY ALSO ADVISED ME THAT ALL THE BRAKE LINES ARE RUSTING AND COULD FAIL AT ANY TIME. I UNDERSTAND THE TRUCK IS 11 YEARS OLD HOWEVER I AM THE ORIGINAL OWNER AND ALWAYS WASHED AND MAINTAINED VEHICLE INCLUDING UNDERCARRIAGE CLEANING. *TR

NHTSA ODI #10564479

77,500 miles · Feb 12, 2014
Service Brakes

I WAS TRAVELING DOWN THE ROAD, WAS APPROACHING A RED LIGHT, APPLIED BRAKES, THEY DID NOT WORK. WENT THROUGH A RED LIGHT, APPLIED EMERGENCY BRAKES, CAME TO A STOP. IMMEDIATELY RETURNED HOME APPLYING EMERGENCY BRAKE, THANK GOD I WAS ONLY AROUND THE BLOCK. UPON EXAMINING THE BRAKES UNDER THE CAR, ALL OF THE LINES WERE RUSTED OUT, …

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I WAS TRAVELING DOWN THE ROAD, WAS APPROACHING A RED LIGHT, APPLIED BRAKES, THEY DID NOT WORK. WENT THROUGH A RED LIGHT, APPLIED EMERGENCY BRAKES, CAME TO A STOP. IMMEDIATELY RETURNED HOME APPLYING EMERGENCY BRAKE, THANK GOD I WAS ONLY AROUND THE BLOCK. UPON EXAMINING THE BRAKES UNDER THE CAR, ALL OF THE LINES WERE RUSTED OUT, CAUSING A LOSS OF ALL BRAKE FLUID. I CONSIDER MYSELF LUCKY, THAT I DID NOT HAVE MY FAMILY WITH ME AND I DID NOT HIT ANOTHER CAR. THIS IS A PROBLEM, DOES SOME ONE HAVE TO BE KILLED FIRST BEFORE THIS IS CONSIDERED A RECALL? *TR

NHTSA ODI #10564032

150,000 miles · Feb 10, 2014
Service Brakes

TL-THE CONTACT OWNS A 2003 CHEVROLET SILVERADO 1500. THE CONTACT STATED THAT THE VEHICLE ROLLED AWAY FROM THE DRIVE WHILE THE GEAR WAS IN PARK POSITION AND CRASHED INTO A TREE. THE MANUFACTURER ADVISED THAT THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER 05V161000 PARKING BRAKE. THE DEALER ADVISED THAT THE PARKING BRAKE FA…

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TL-THE CONTACT OWNS A 2003 CHEVROLET SILVERADO 1500. THE CONTACT STATED THAT THE VEHICLE ROLLED AWAY FROM THE DRIVE WHILE THE GEAR WAS IN PARK POSITION AND CRASHED INTO A TREE. THE MANUFACTURER ADVISED THAT THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER 05V161000 PARKING BRAKE. THE DEALER ADVISED THAT THE PARKING BRAKE FAILED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE AND CURRENT MILEAGE WAS 150,000. LI

NHTSA ODI #10563678

134,920 miles · Feb 9, 2014
Service Brakes

AS I WAS DRIVING AND USING THE BRAKES I NOTICED THAT THE BRAKE PEDAL WAS GOING FURTHER AND FURTHER TO THE FLOOR. WHEN I GOT HOME I NOTICED THAT FLUID WAS LEAKING FROM THE REAR OF THE VEHICLE. THE LEAK WAS FROM A REAR BRAKE LINE THAT HAD COMPLETELY RUSTED THROUGH. I LOOKED AT THE OTHER BRAKE LINES AND NOTICED THAT THEY WERE ALL S…

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AS I WAS DRIVING AND USING THE BRAKES I NOTICED THAT THE BRAKE PEDAL WAS GOING FURTHER AND FURTHER TO THE FLOOR. WHEN I GOT HOME I NOTICED THAT FLUID WAS LEAKING FROM THE REAR OF THE VEHICLE. THE LEAK WAS FROM A REAR BRAKE LINE THAT HAD COMPLETELY RUSTED THROUGH. I LOOKED AT THE OTHER BRAKE LINES AND NOTICED THAT THEY WERE ALL SEVERELY CORRODED. TOOK THE TRUCK TO CHEVROLET DEALERSHIP AND WAS TOLD THAT ALL THE BRAKE LINES NEEDED TO BE REPLACED DUE TO THE CORROSION. THEY WERE CONCERNED THAT THE OTHER BRAKE LINES COULD LEAK AT ANY TIME. I HAD THE LINES REPLACED AT THE DEALERSHIP AT A COST OF $2600.00. THIS IS A VERY SERIOUS DEFECT THAT COULD HAVE BEEN CATASTROPHIC. *TR

NHTSA ODI #10563563

82,300 miles · Feb 5, 2014
Service Brakes

DRIVING ALONG COMING TO A CURVE, I APPLIED BRAKES AND PEDAL WENT TO THE FLOOR AND ABS LIGHT CAME ON. I SLOWED DOWN BY DOWNSHIFTING AND STOPPED ON SIDE OF ROAD USING PARKING BRAKE. I LOOKED UNDER VEHICLE AND SAW FLUID DRIPPING DOWN THE FRAME BY DRIVERS DOOR. I HAD TO PAY TO HAVE TRUCK TOWED HOME. FRONT BRAKE LINE WAS COMPROMI…

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DRIVING ALONG COMING TO A CURVE, I APPLIED BRAKES AND PEDAL WENT TO THE FLOOR AND ABS LIGHT CAME ON. I SLOWED DOWN BY DOWNSHIFTING AND STOPPED ON SIDE OF ROAD USING PARKING BRAKE. I LOOKED UNDER VEHICLE AND SAW FLUID DRIPPING DOWN THE FRAME BY DRIVERS DOOR. I HAD TO PAY TO HAVE TRUCK TOWED HOME. FRONT BRAKE LINE WAS COMPROMISED FROM THE MASTER CYLINDER TO ABS PUMP. I REPLACED BOTH LINES FROM MASTER CYLINDER TO ABS PUMP. THE REST OF BRAKE LINES HAD SOME RUST BUT LOOKED LIKE SURFACE ONLY. SECOND INCIDENT: ON 18 NOVEMBER 2013, I WAS CARRYING AROUND 800 POUNDS OF STONE FOR MY LIVING ROOM WALL WHEN THE BRAKE PEDAL WENT TO THE FLOOR AT AROUND 45 MPH, AS I WAS STOPPING FOR A RED LIGHT. I RAN THE LIGHT AND TURNED RIGHT AND GOT THE TRUCK STOPPED. LOOKED UNDERNEATH AND SAW FLUID DRIPPING OFF FRAME BY THE FUEL TANK. NURSED THE TRUCK HOME THE LAST MILE WITH A FRIEND DRIVING HIS TRUCK IN FRONT OF ME. THE REAR BRAKE LINE FROM THE ABS PUMP TO THE REAR END RUSTED THROUGH BEHIND THE FUEL TANK. NO WAY OF SEEING THIS FAILURE COMING. MILEAGE ON TRUCK AROUND 91,500. *TR

NHTSA ODI #10563168

113,000 miles · Jan 16, 2014
Service Brakes

I APPLIED BRAKES COMING UP TO A RED LIGHT. VEHICLE DID NOT STOP AND PEDAL PUSHED TO THE FLOOR. APPLIED E-BRAKE TO STOP AND RESUMED TO REPAIR SHOP ON OTHER SIDE OF LIGHTS. FOUND BRAKE LINE HAD PIN HOLES. *TR

NHTSA ODI #10560305

70,000 miles · Jan 13, 2014
Service Brakes

TL* THE CONTACT OWNS A 2003 CHEVROLET SILVERADO 1500. THE CONTACT STATED THAT WHILE DECELERATING, THE ABS ERRONEOUSLY ACTIVATED. THE CONTACT STATED THAT THE FAILURE WAS ALSO PRESENT ON DRY PAVEMENT AND CAUSED AN INCREASE IN STOPPING DISTANCE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE FAILU…

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TL* THE CONTACT OWNS A 2003 CHEVROLET SILVERADO 1500. THE CONTACT STATED THAT WHILE DECELERATING, THE ABS ERRONEOUSLY ACTIVATED. THE CONTACT STATED THAT THE FAILURE WAS ALSO PRESENT ON DRY PAVEMENT AND CAUSED AN INCREASE IN STOPPING DISTANCE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE FAILURE MILEAGE WAS 70,000. THE VIN WAS NOT AVAILABLE.

NHTSA ODI #10559611

185,591 miles · Dec 28, 2013
Service Brakes

ON AUGUST 7, 2013, I WAS HEADING INTO RICHMOND, KY AND WAS APPROACHING A STOP LIGHT. I BEGAN TO LIGHTLY APPLY PRESSURE ON THE BRAKE AND BEGAN TO SLOW DOWN. AS I CONTINUED TO APPLY MORE PRESSURE, THE BRAKE PEDAL WENT TO THE FLOOR AND I HAD NO BRAKE PRESSURE. I HAD NO WARNING LIGHTS OR MESSAGES ON THE DASH BOARD AT TH…

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ON AUGUST 7, 2013, I WAS HEADING INTO RICHMOND, KY AND WAS APPROACHING A STOP LIGHT. I BEGAN TO LIGHTLY APPLY PRESSURE ON THE BRAKE AND BEGAN TO SLOW DOWN. AS I CONTINUED TO APPLY MORE PRESSURE, THE BRAKE PEDAL WENT TO THE FLOOR AND I HAD NO BRAKE PRESSURE. I HAD NO WARNING LIGHTS OR MESSAGES ON THE DASH BOARD AT THIS TIME. I CONTINUED TO PUMP THE BRAKES IN AN ATTEMPT TO REGAIN BRAKE PRESSURE BUT WAS NOT SUCCESSFUL. WHILE STILL PRESSING THE BRAKE PEDAL NEAR THE FLOOR, I NOTICED THE VEHICLE WAS BEGINNING TO SLOW DOWN, BUT NOT ENOUGH TO STOP AT THE LIGHT. FORTUNATELY NO ONE WAS IN FRONT OF ME OR AT THE INTERSECTION AS I APPROACHED IT. I USED THE UPCOMING HILL TO CONTINUE TO SLOW DOWN AND EVENTUALLY MADE IT TO A VACANT PARKING LOT. ONCE I CAME TO A STOP THE VEHICLE DASH BOARD LIGHTS APPEARED ABOUT THE BRAKE SYSTEM ISSUES. AFTER CONTACTING THE LOCAL GM SERVICE STATION, I WAS ABLE TO PUT THE VEHICLE IN 1ST GEAR AND SLOWLY MAKE MY WAY TO THE SERVICE LOCATION ON SIDE ACCESS ROADS. THE DEALERSHIP DETERMINED THAT ALL THE BRAKE LINES WERE RUSTED AND SEVERAL HAD FAILED. THIS CAUSED THE BRAKE FAILURE AND THEY ALL NEEDED REPLACED. THE REPAIR COST WAS OVER $2300. MY TRUCK HAD 185,591 MILES AT THE TIME OF THE INCIDENT. I HAD RECENTLY MOVED TO KY BUT WAS LIVING IN OHIO FOR MOST OF THE OWNERSHIP OF THE TRUCK. *TR

NHTSA ODI #10557524

95,000 miles · Dec 20, 2013
Service Brakes

BRAKE LINES RUSTED OUT. HAD TO DRIVE 60 MILES AND CHOSE EARLY MORNING DUE TO HAVING ALMOST BRAKING POWER. WE HAVE A FORD TRUCK OF THE SAME YEAR AND THE BRAKE LINES ARE STILL VERY GOOD. THERE IS NO EXCUSE FOR THIS OTHER THAN A GOOD COMPANY GOING ON THE CHEAP. !!!! *TR

NHTSA ODI #10556856

Official recalls

0

No recalls in this snapshot.

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

3

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

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.

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.