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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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153,390 miles · Dec 6, 2013
Fuel System, GasolineService BrakesVehicle Speed Control

MY WIFE WAS DRIVING OUR 2003 CHEVROLET SILVERADO 4X4 PICKUP ON SECONDARY STATE ROUTE. WHILE DESCENDING AN APPROXIMATE 6% GRADE INTO A RIGHT HAND TURN AT BOTTOM SHE DEPRESSED THE BRAKE PEDAL TO SLOW FOR THE GRADE AND TURN AND IT WENT TO THE FLOOR, THE SERVICE BRAKE MESSAGE CAME UP IN THE DIC AND THE DOOR CHIME SOUNDED. SHE PULL…

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MY WIFE WAS DRIVING OUR 2003 CHEVROLET SILVERADO 4X4 PICKUP ON SECONDARY STATE ROUTE. WHILE DESCENDING AN APPROXIMATE 6% GRADE INTO A RIGHT HAND TURN AT BOTTOM SHE DEPRESSED THE BRAKE PEDAL TO SLOW FOR THE GRADE AND TURN AND IT WENT TO THE FLOOR, THE SERVICE BRAKE MESSAGE CAME UP IN THE DIC AND THE DOOR CHIME SOUNDED. SHE PULLED OVER AS SOON AS POSSIBLE AS SHE WAS SHAKEN FROM RIDING OUT THAT HILL AND TURN WITH MINIMAL BRAKES AND CALLED ME. I WENT OUT AND DROVE THE TRUCK BACK TO OUR HOME AND PUT IN THE GARAGE TO INSPECT THE PROBLEM. ONCE UNDER THE TRUCK I FOUND BRAKE FLUID DRIPPING FROM THE SIDE OF THE FUEL TANK AND FRAME AREA UNDER THE CAB AND BED OF THE TRUCK. THE SERVICE BRAKE LINE FROM THE ABS BLOCK TO THE REAR FRAME POINT WHERE THE BRAKE HOSE TO THE REAR AXLE MOUNTS WAS CORRODED THROUGH AND LEAKING. FURTHER INSPECTION SHOWED ALL BRAKE HARD LINE PLUMBING TO BE IN POOR CONDITION AND ALSO THE FUEL LINES SHOWING HIGH CORROSION. A CALL TO A LOCAL GM PARTS COUNTER REVEALED THAT GM DOES NOT MAKE A REPLACEMENT SET FOR THESE LINES AND THAT A TECHNICIAN WOULD NEED TO FIELD BEND AND MAKE UP EACH LINE. LATER RESEARCH PROVED THIS TO BE WRONG AS GM OFFERS A DEEPLY DISCOUNTED UNADVERTISED LINE SET FROM AC DELCO. IN RESEARCHING FINDING PARTS TO REPAIR, I HAVE FOUND THIS TO BE A COMMON PROBLEM WITH CHEVROLET/GMC TRUCKS FROM ABOUT 1999 UP ACCORDING TO THE VARIOUS TRUCK OWNER FORUMS ONLINE. DRIVING THE VEHICLE HOME AT SLOW SPEED, BRAKING WAS VERY MINIMAL WITH THE REAR BRAKE CIRCUIT OUT,AND THE KNOWLEDGE OF POOR BRAKE OPERATION, SO THEREFORE IT IS MY OPINION THAT THIS IS A SAFETY ISSUE WITH THESE VEHICLES WITH THE POTENTIAL OF INJURY OR EVEN DEATH WHEN ALL THE FACTORS COMBINE POORLY, AND AT THE LEAST, GM SHOULD BE REQUIRED TO NOTIFY OWNERS OF THIS POTENTIAL PROBLEM WITH THEIR VEHICLE, IF NOT RECALL AND REPAIR THOSE EFFECTED VEHICLES. *TR

NHTSA ODI #10555068

176,000 miles · Dec 5, 2013
Service Brakes

WHILE ATTEMPTING TO STOP IN FRONT OF A STORE MY BRAKE PEDAL WENT TO THE FLOOR I SHIFTED INTO PARK TO AVOID HITTING THE PERSON IN THE CROSSWALK. MY TRUCK WAS TOWED TO THE DEALER AND I WAS TOLD ALL BRAKE LINES WERE COMPLETELY RUSTED THE GM REP TOLD ME IT WAS AN OLD TRUCK WITH MANY MILES AS A RETIRED GM EMPLOYEE AND A LICENSED MECH…

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WHILE ATTEMPTING TO STOP IN FRONT OF A STORE MY BRAKE PEDAL WENT TO THE FLOOR I SHIFTED INTO PARK TO AVOID HITTING THE PERSON IN THE CROSSWALK. MY TRUCK WAS TOWED TO THE DEALER AND I WAS TOLD ALL BRAKE LINES WERE COMPLETELY RUSTED THE GM REP TOLD ME IT WAS AN OLD TRUCK WITH MANY MILES AS A RETIRED GM EMPLOYEE AND A LICENSED MECHANIC I HAVE DRIVEN MANY OLDER CARS AND NEVER SEEN THIS KIND OF RUSTED OUT BRAKE LINES . WILL IT TAKE A FEW DEATHS AND LAWSUITS BEFORE OWNERS OF THESE TRUCKS ARE WARNED? *TR

NHTSA ODI #10554883

68,000 miles · Dec 4, 2013
Service Brakes

TL* THE CONTACT OWNS A 2003 CHEVROLET SILVERADO 1500. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 45 MPH, THE BRAKES WERE ENGAGED BUT THE BRAKE PEDAL SUNK INTO THE FLOORBOARD AND FAILED TO STOP THE VEHICLE. THE CONTACT MENTIONED THAT THE SERVICE BRAKE SYSTEM WARNING LIGHT WAS ILLUMINATED. THE VEHICLE WAS NOT TAKEN TO A D…

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TL* THE CONTACT OWNS A 2003 CHEVROLET SILVERADO 1500. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 45 MPH, THE BRAKES WERE ENGAGED BUT THE BRAKE PEDAL SUNK INTO THE FLOORBOARD AND FAILED TO STOP THE VEHICLE. THE CONTACT MENTIONED THAT THE SERVICE BRAKE SYSTEM WARNING LIGHT WAS ILLUMINATED. THE VEHICLE WAS NOT TAKEN TO A DEALER FOR DIAGNOSTIC TESTING OR REPAIRS. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE AND CURRENT MILEAGE WAS 68,000.

NHTSA ODI #10554792

90,800 miles · Nov 25, 2013
Service Brakes

THE BRAKES BEGAN FAILING AS WE WERE DRIVING TO WORK. MY WIFE CAREFULLY DROVE THE TRUCK STRAIGHT TO THE REPAIR SHOP AND BARELY MANAGED TO STOP IT. MECHANIC REPORTED THAT SEVERAL BRAKE LINES WERE LEAKING DUE TO CORROSION. THAT'S NOT SURPRISING CONSIDERING EVERYTHING UNDERNEATH THE CHASSIS IS CORRODING RAPIDLY. MOST CORROSION PRONE…

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THE BRAKES BEGAN FAILING AS WE WERE DRIVING TO WORK. MY WIFE CAREFULLY DROVE THE TRUCK STRAIGHT TO THE REPAIR SHOP AND BARELY MANAGED TO STOP IT. MECHANIC REPORTED THAT SEVERAL BRAKE LINES WERE LEAKING DUE TO CORROSION. THAT'S NOT SURPRISING CONSIDERING EVERYTHING UNDERNEATH THE CHASSIS IS CORRODING RAPIDLY. MOST CORROSION PRONE VEHICLE I'VE OWNED IN 25 YEARS. THIS VEHICLE SHOULD HAVE BEEN RECALLED FOR CORROSION AND ELECTRICAL PROBLEMS WHICH I'M CONSTANTLY DEALING WITH. *TR

NHTSA ODI #10553727

96,345 miles · Nov 24, 2013
Service Brakes

THE BRAKE PEDAL WAS DEPRESSED AND THE PEDAL WENT TO THE FLOOR. I WAS ABLE TO GET THE TRUCK BACK TO MY HOUSE. LOOKING UNDER THE DRIVERS SIDE REAR WHEEL, BRAKE FLUID COULD BE SEEN DRIPPING FROM A BRAKE LINE. *TR

NHTSA ODI #10553644

120,771 miles · Nov 23, 2013
Service Brakes

PULLING INTO MY DRIVEWAY THE BRAKES WENT TO THE FLOOR AND ALMOST HIT MY OTHER CAR. STEERED AROUND IT AND WENT INTO THE YARD. AFTER CHECKING MY TRUCK I FOUND A METAL BRAKE LINE UNDER THE DRIVER DOOR RUSTED AND LEAKING FLUID. VERY LUCKY IT HAPPENED AT HOME I GUESS. *TR

NHTSA ODI #10553540

137,882 miles · Nov 11, 2013
Fuel System, GasolineService BrakesStructure

WELL ABOUT MID 2012 THE BRAKE LINES JUST RUST OUT IN THE MIDDLE OF THE TRUCK AND THE REAR. MY GIRL FRIEND WAS DRIVING IT TO WORK AND LOST ALL THE PEDAL PRESSURE. THANK GOD SHE WAS GOING UP IN THE PARKING GARAGE. RIGHT NOW I'M TRYING TO REPLACE LINE FUEL LINES. IT JUST STARTED POURING GAS OUT AFTER I JUST GOT TO WORK. I NURSED I…

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WELL ABOUT MID 2012 THE BRAKE LINES JUST RUST OUT IN THE MIDDLE OF THE TRUCK AND THE REAR. MY GIRL FRIEND WAS DRIVING IT TO WORK AND LOST ALL THE PEDAL PRESSURE. THANK GOD SHE WAS GOING UP IN THE PARKING GARAGE. RIGHT NOW I'M TRYING TO REPLACE LINE FUEL LINES. IT JUST STARTED POURING GAS OUT AFTER I JUST GOT TO WORK. I NURSED IT HOME AND MADE IT. THE RETURN LINE IS JUST ALL RUSTED OUT. THEN I NOTICED ALL THREE LINES WHERE ALL RUSTED OUT. IT'S TO BAD NOTHING HAS BEEN DONE YET I CAN'T AFFORD THIS! IT IS WELL KNOWN AND UNDERSTOOD BY MANY THAT THIS IS A BIG PROBLEM. ALSO TO TOP THAT THE FRAME LOOKS MORE RUSTED THAN THE 1989 DODGE I JUST GOT RIDE OF. I WASH UNDER THE TRUCK THROUGH OUT WINTER AND DON'T UNDERSTAND WHY IT'S SO BAD ALREADY. *TR

NHTSA ODI #10551832

81,748 miles · Nov 9, 2013
Service Brakes

I WAS DRIVING MY 2003 CHEVROLET SILVERADO 1500 LATE AT NIGHT WHEN A DEER ENTERED MY LANE OF TRAVEL. I DEPRESSED THE BRAKE PEDAL BUT NOTHING HAPPENED. I LUCKILY AVOIDED THE DEER BY SWERVING. I WAS ABLE TO GET THE VEHICLE BACK TO MY RESIDENCE BY DRIVING IN FIRST GEAR AND USING THE EMERGENCY BRAKE. WHEN HOME I LOOKED UNDER THE …

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I WAS DRIVING MY 2003 CHEVROLET SILVERADO 1500 LATE AT NIGHT WHEN A DEER ENTERED MY LANE OF TRAVEL. I DEPRESSED THE BRAKE PEDAL BUT NOTHING HAPPENED. I LUCKILY AVOIDED THE DEER BY SWERVING. I WAS ABLE TO GET THE VEHICLE BACK TO MY RESIDENCE BY DRIVING IN FIRST GEAR AND USING THE EMERGENCY BRAKE. WHEN HOME I LOOKED UNDER THE VEHICLE AND NOTICED BRAKE FLUID LEAKING FROM ONE OF THE CORRODED BRAKE LINES ON THE OUTSIDE OF THE FRAME (DRIVER'S SIDE) WHERE IT BENDS TO GO INTO THE ABS MODULE. FURTHER INSPECTION REVEALED THAT THE LINES ARE COMPLETELY CORRODED CLEAR UP ALONG THE FRAME AND WHERE THEY ENTER INTO THE BRAKE RESERVOIR. NOTICING THIS, I AM NOW GOING TO HAVE TO REPLACE ALL OF THE LINES SO THAT I DON'T HAVE THIS HAPPEN AGAIN. THESE LINES ARE A DANGER AND SHOULD BE REPLACED BY GM. IF THIS WOULD HAVE HAPPENED IN TRAFFIC, ESPECIALLY SLOWING DOWN FOR A LIGHT OR STOP SIGN, AN ACCIDENT WOULD HAVE MOST LIKELY HAPPENED. I WOULD RECOMMEND TO ANYONE THAT IS READING THIS TO VISUALLY INSPECT YOUR BRAKE LINES. A LARGE PORTION OF THE LINES CAN BE SEEN BY SIMPLY LAYING DOWN IN THE AREA OF THE DRIVER'S SIDE DOOR TO THE FRONT WHEEL, AND LOOKING AT THE FRAME TO WHERE THEY ARE ATTACHED. *TR

NHTSA ODI #10551595

47,305 miles · Nov 8, 2013
Service Brakes

TL* THE CONTACT OWNS A 2003 CHEVROLET SILVERADO 1500. THE CONTACT STATED THAT WHILE DRIVING 5 MPH, HE ATTEMPTED TO ENGAGE THE BRAKES BUT THE BRAKE PEDAL SUNK ABNORMALLY INTO THE FLOORBOARD. THE CONTACT THEN ATTEMPTED TO ENGAGE THE EMERGENCY BRAKE BUT IT ALSO FAILED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE TECHNICIAN DIAGNO…

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TL* THE CONTACT OWNS A 2003 CHEVROLET SILVERADO 1500. THE CONTACT STATED THAT WHILE DRIVING 5 MPH, HE ATTEMPTED TO ENGAGE THE BRAKES BUT THE BRAKE PEDAL SUNK ABNORMALLY INTO THE FLOORBOARD. THE CONTACT THEN ATTEMPTED TO ENGAGE THE EMERGENCY BRAKE BUT IT ALSO FAILED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE TECHNICIAN DIAGNOSED THAT THE BRAKE LINES WERE COMPLETELY CORRODED. AS A RESULT, THE BRAKE LINES AND THE CALIPERS WOULD NEED REPLACING. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 47,305. UPDATED 12/20/13*CN

NHTSA ODI #10551494

63,000 miles · Oct 19, 2013
Service Brakes

WAS PULLING INTO A PARKING LOT TOWING A TRAILER WHEN THE BRAKE PEDAL WENT TO THE FLOOR. I WAS ABLE TO AVOID OTHER VEHICLES AND GO IN CIRCLES TILL VEHICLE FINALLY WAS ABLE TO BE STOPPED. I HAD NO BRAKES AT ALL AND UPON INSPECTION FOUND THAT A BRAKE LINE HAD RUPTURED. I ALSO NOTICED THAT ALL THE BRAKE LINES UNDER THE VEHICLE WERE …

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WAS PULLING INTO A PARKING LOT TOWING A TRAILER WHEN THE BRAKE PEDAL WENT TO THE FLOOR. I WAS ABLE TO AVOID OTHER VEHICLES AND GO IN CIRCLES TILL VEHICLE FINALLY WAS ABLE TO BE STOPPED. I HAD NO BRAKES AT ALL AND UPON INSPECTION FOUND THAT A BRAKE LINE HAD RUPTURED. I ALSO NOTICED THAT ALL THE BRAKE LINES UNDER THE VEHICLE WERE EXTREMELY CORRODED. THIS WOULD HAVE BEEN DRASTIC HAD IT HAPPENED ON THE ROAD AT A STOP LIGHT OR INTERSECTION, I OR SOMEONE ELSE WOULD CERTAINLY HAD BEEN KILLED OR SERIOUSLY INJURED. I UNDERSTAND THAT NHTSA AND CHEVY ARE AWARE OF THE BRAKE LINE RUSTING OUT PROBLEM WITH THESE TRUCKS AND REFUSE TO DO ANYTHING ABOUT IT ? *TR

NHTSA ODI #10548502

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.