IllustrationSLOWING AT A TRAFFIC LIGHT I NOTICED THE PEDAL DEPRESSING MORE THAN NORMAL. AT LIGHT THE PEDAL DEPRESSED TO THE FLOOR OF THE CAR, BRAKE LIGHT CAME ON. UNSAFE RIDE HOME WITH ALMOST ZERO BRAKING. LEFT FRONT BRAKE LINE WAS RUSTED OUT. *TR
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.
About this comparison →How this year compares
Owner complaints by model year
Compare all Silverado 1500 years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
560–25K
11025–50K
15450–75K
15275–100K
175100–150K
79150K+
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
What owners actually said
805 reportsDRIVING DOWN 2 LANE ROAD AT APPROXIMATELY 40 IN A 45 MPH ZONE. TRAFFIC LIGHT TURNED YELLOW AT THE WORST POSSIBLE MOMENT. DECIDED TO PANIC STOP, PRESSED THE PEDAL HARD, IMMEDIATELY THE PEDAL WENT TO THE FLOOR AND THE BRAKE WARNING CAME ON. TRUCK DID NOT HAVE SUFFICIENT BRAKING TO STOP AND I HAD TO PLOW THROUGH THE INTERSECTION…
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DRIVING DOWN 2 LANE ROAD AT APPROXIMATELY 40 IN A 45 MPH ZONE. TRAFFIC LIGHT TURNED YELLOW AT THE WORST POSSIBLE MOMENT. DECIDED TO PANIC STOP, PRESSED THE PEDAL HARD, IMMEDIATELY THE PEDAL WENT TO THE FLOOR AND THE BRAKE WARNING CAME ON. TRUCK DID NOT HAVE SUFFICIENT BRAKING TO STOP AND I HAD TO PLOW THROUGH THE INTERSECTION, THANK GOD I MADE IT THROUGH SAFELY. FROM THIS POINT UNTIL I REACHED HOME, VERY LITTLE BRAKING WAS POSSIBLE, VERY UNSAFE. UPON INSPECTION, THE REAR LINE HAD BURST, REQUIRING $200 IN REPAIRS. A FEW MONTHS EARLIER THE GAS LINE RUSTED THROUGH ALSO, COSTING ANOTHER $200. *TR
TL* THE CONTACT OWNS A 2003 CHEVROLET SILVERADO 1500. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 40 MPH, THE SPEEDOMETER DISPLAYED AN INACCURATE READING OF 80 MPH. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE INSTRUMENT CLUSTER NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE.…
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TL* THE CONTACT OWNS A 2003 CHEVROLET SILVERADO 1500. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 40 MPH, THE SPEEDOMETER DISPLAYED AN INACCURATE READING OF 80 MPH. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE INSTRUMENT CLUSTER NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 81,000 AND THE CURRENT MILEAGE WAS 84,000. THE VIN WAS NOT AVAILABLE. *TR
TRUCK EXPERIENCED CATASTROPHIC BRAKE FAILURE WHEN A CORRODED RIGHT FRONT BRAKE LINE RUPTURED DURING AN ATTEMPTED HARD STOP AT A TRAFFIC LIGHT. THE BRAKE PEDAL WENT STRAIGHT TO THE FLOOR AND THE TRUCK CONTINUED THROUGH THE INTERSECTION. PUMPING THE BRAKE PEDAL HAD NO EFFECT. SHIFTING THE TRANSMISSION DOWN AND APPLYING THE EMER…
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TRUCK EXPERIENCED CATASTROPHIC BRAKE FAILURE WHEN A CORRODED RIGHT FRONT BRAKE LINE RUPTURED DURING AN ATTEMPTED HARD STOP AT A TRAFFIC LIGHT. THE BRAKE PEDAL WENT STRAIGHT TO THE FLOOR AND THE TRUCK CONTINUED THROUGH THE INTERSECTION. PUMPING THE BRAKE PEDAL HAD NO EFFECT. SHIFTING THE TRANSMISSION DOWN AND APPLYING THE EMERGENCY BRAKE EVENTUALLY STOPPED THE TRUCK. FLUID LEAKING FROM THE RUPTURE DRAINED THE MASTER CYLINDER RESERVOIR WITHIN FIVE MINUTES. SUBSEQUENT INSPECTION OF ALL THE BRAKE LINES REVEALED SEVERE CORROSION AND PITTING AT MANY LOCATIONS ALONG THE LENGTH OF THE TRUCK. DESPITE HAVING THE FRONT AND REAR BRAKES ON SEPARATE HYDRAULIC CIRCUITS, THERE WAS NOT ENOUGH BRAKING CAPABILITY REMAINING TO SAFELY DRIVE THE TRUCK, EVEN AT LOW SPEEDS. THIS WAS A VERY CLOSE CALL AND IT IS EVIDENT THAT THE CORROSION RESISTANCE OF THE BRAKE LINES IS SUBSTANDARD, POSING A HUGE SAFETY CONCERN.
THE TIRES WERE PURCHASED 3 YEARS AGO. AFTER THE FIRST MONTH OF PURCHASE I RETURNED THE VEHICLE TO THE RETAILER WITH PEELING ON ALL FOUR SIDEWALLS. I CHOOSE TO HAVE THESE TIRES MOUNTED WITH THE WHITE LETTERING TO THE OUTSIDE AND THE PEELING WAS ON THE BLACK PART OF THE TIRES ALL OVER EVEN BETWEEN THE LETTERING. THE MANAGER INF…
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THE TIRES WERE PURCHASED 3 YEARS AGO. AFTER THE FIRST MONTH OF PURCHASE I RETURNED THE VEHICLE TO THE RETAILER WITH PEELING ON ALL FOUR SIDEWALLS. I CHOOSE TO HAVE THESE TIRES MOUNTED WITH THE WHITE LETTERING TO THE OUTSIDE AND THE PEELING WAS ON THE BLACK PART OF THE TIRES ALL OVER EVEN BETWEEN THE LETTERING. THE MANAGER INFORMED ME I HAD RAN AGAINST SOME CURBING-NOW HOW DOES ONE RUN UP AGAINST CURBING WITH ALL FOUR TIRES AT ONE TIME AND NOT EVEN SCAR UP THE TIRE OR THE LETTERING? IN MY ESTIMATION THIS COULD NOT HAPPEN. HE INFORMED ME IT WAS A COSMETIC DEFECT AND WOULD DO NOTHING ABOUT IT. THE SITUATION BECAME INCREASINGLY WORSE THROUGHOUT THE REMAINDER OF TIME WITH NUMEROUS FLATS, UNEVEN WEAR AND EXTREME VIBRATION. THIS IS A COMPANY VEHICLE AND DUE TO LIABILITY REASONS AND LACK OF SUPPORT FROM THE RETAILER, THE VEHICLE WAS DRIVEN ONLY 10,000 MILES PER YEAR ON THESE TIRES. MY EMPLOYEE CALLED AND INFORMED ME OF A FLAT ON THE VEHICLE AND THE OTHER 3 TIRES WERE AT THE POINT WHERE THE STEEL BELTS WERE SHOWING THROUGH. AT THIS POINT I CONTACTED THE MANAGER AT THE RETAILER ONLY TO BE TOLD I WOULD BE GIVEN CREDIT OF $49.00 PER TIRE EVEN THOUGH I HAD TROUBLE FROM THE VERY BEGINNING. I PERSONALLY FEEL LIKE THESE TIRES SHOULD HAVE BEEN ON THE RECALL LIST FROM THE VERY BEGINNING BUT NOW I WILL BE FORCED TO PAY FULL PRICE AT ANOTHER DISTRIBUTOR FOR ANOTHER SET OF TIRES. THE TIRES ON OUR VEHICLES ARE OUR LIVELIHOOD SINCE THIS IS A SALESMEN VEHICLE AND MANY MORE DOLLARS IN SALES COULD HAVE BEEN MADE HAD I NOT BEEN AFRAID FROM A LIABILITY STANDPOINT. RIGHT NOW I CAN'T AFFORD TO MAKE A DECISION ON THIS SINCE NEW TIRES HAVE NOT BEEN BUDGETED FOR THIS VEHICLE AND WE HAVE NO EXTRA ONES AT THIS TIME. FOR DISCOUNT TIRES SAKE I HOPE THERE ARE NO ACCIDENTS THAT TAKE PLACE IN THIS VEHICLE. *TR
(*AFFECTED PART - IT DOESN'T LET ME TO TYPE IPC - INSTRUMENT PANEL CLUSTER) FUEL NEEDLE IS NOT OPERATING - COMPLETELY. BATTERY VOLTAGE NEEDLE - IS NOT OPERATING - COMPLETELY. SPEEDOMETER IS STICKING. LIGHTS AT DASHBOARD ARE DIM, TAKES COUPLE MINUTES TO GET BACK TO NORMAL. GM IS AWARE OF DEFECTIVE PRODUCT (IPC - INSTRUMENT …
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(*AFFECTED PART - IT DOESN'T LET ME TO TYPE IPC - INSTRUMENT PANEL CLUSTER) FUEL NEEDLE IS NOT OPERATING - COMPLETELY. BATTERY VOLTAGE NEEDLE - IS NOT OPERATING - COMPLETELY. SPEEDOMETER IS STICKING. LIGHTS AT DASHBOARD ARE DIM, TAKES COUPLE MINUTES TO GET BACK TO NORMAL. GM IS AWARE OF DEFECTIVE PRODUCT (IPC - INSTRUMENT PANEL CLUSTER) THAT WAS INSTALLED ON ALL 2003 AND 2004 CHEVY SILVERADO, BUT IS REFUSING TO CORRECT A PROBLEM. THEY ISSUED ONLY SHORT TERM "SPECIAL COVERAGE", WHICH EXPIRED IN 04/2010, WITHOUT EVEN NOTIFYING ALL OF OWNERS ABOUT DEFECT, SO - GOD FORBID - THEY WON'T GO TO DEALERSHIP AND HAVE IT REPLACED AT THAT TIME. IT'S A SERIOUS SAFETY ISSUE, AND GM SHOULD BE RESPONSIBLE FOR CORRECTING IT. I AM DRIVING NOT KNOWING HOW MUCH GASOLINE IS IN MY TANK, IS MY BATTERY VOLTAGE OK OR REALLY HAS PROBLEM, WHAT IS MY SPEED AND IF IT COMPLIES WITH SPEED LIMIT, AND AT NIGHT I EVEN DON'T SEE DASHBOARD INFO. GM SAYS - "IT'S YOUR PROBLEM, NOT OUR. TAKE CARE OF IT ON YOUR OWN". I PURCHASED VEHICLE IN GOOD FAITH THAT ALL PARTS ARE IN GOOD WORKING CONDITION. IN REALITY THAT WAS NOT A CASE. GM INSTALLED DEFECTIVE PARTS ON THEIR VEHICLE AND SHOULD CARRY FULL RESPONSIBILITY FOR REPLACING THEM WITH GOOD ONES. *TR
APPROACHING A 3 WAY STOP INTERSECTION, UPON DEPRESSING THE BRAKE PEDAL IN ORDER TO STOP AT THE INTERSECTION, THE BRAKE PEDAL WENT TO THE FLOOR. NO WARNING LAMPS OF ANY SORT WERE ILLUMINATED PRIOR TO THE BRAKE PEDAL GOING TO THE FLOOR. PUMPING OF THE PEDAL DID NOT PRODUCE ANY RESISTANCE. AFTER COUPLE MINUTES THE "SERVICE BRAKES" …
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APPROACHING A 3 WAY STOP INTERSECTION, UPON DEPRESSING THE BRAKE PEDAL IN ORDER TO STOP AT THE INTERSECTION, THE BRAKE PEDAL WENT TO THE FLOOR. NO WARNING LAMPS OF ANY SORT WERE ILLUMINATED PRIOR TO THE BRAKE PEDAL GOING TO THE FLOOR. PUMPING OF THE PEDAL DID NOT PRODUCE ANY RESISTANCE. AFTER COUPLE MINUTES THE "SERVICE BRAKES" WARNING CAME ON. I WAS ABLE TO BRING THE TRUCK TO A STOP BY SLOWING DOWN. HAD TO HAVE THE TRUCK TOWED TO A FIRESTONE SERVICE CENTER THE TECHNICIAN, THE SERVICE CONSULTANT, AND I ALL OBSERVED THE RUSTED BRAKE LINES, THEY WERE ALL BADLY CORRODED, ONE OF THE LINES HAD DEVELOPED A PIN HOLE LEAD RESULTING IN THE BRAKE FAILURE. I HAVE OWNED MANY VEHICLES FAR OLDER AND WITH FAR MORE MILEAGE AND HAVE NEVER HAD TO REPLACE THE STEEL BRAKE LINES. I BELIEVE THE DESIGN IS FLAWED (THE ROUTING AND PLACEMENT OF LINES AND MODULE) OR THE BRAKE LINE MATERIAL (STEEL, INSTEAD OF STAINLESS STEEL) IS INSUFFICIENT. *TR
TL* THE CONTACT OWNS A 2003 CHEVROLET SILVERADO C1500. THE CONTACT STATED THAT HE TRIED TO STOP THE VEHICLE AND THE BRAKE WENT ALL THE WAY TO FLOOR. THE VEHICLE WAS TOWED TO A LOCAL MECHANIC WHO INSPECTED THE FAILURE AND STATED THAT THE ENTIRE BRAKE LINE NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIF…
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TL* THE CONTACT OWNS A 2003 CHEVROLET SILVERADO C1500. THE CONTACT STATED THAT HE TRIED TO STOP THE VEHICLE AND THE BRAKE WENT ALL THE WAY TO FLOOR. THE VEHICLE WAS TOWED TO A LOCAL MECHANIC WHO INSPECTED THE FAILURE AND STATED THAT THE ENTIRE BRAKE LINE NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED WHO OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS 69,974. UPDATED 05/10/13*LJ THE CONSUMER STATED THE BRAKE LINES RUSTED CAUSING BRAKE FLUIDS TO LEAK OUT. UPDATED 05/28/2013 *JS
HAD JUST DRIVEN 30 MILES ON BACKROADS TO MY PARENTS HOUSE TO PICKUP AN ENCLOSED RACE TRAILER (FULLY LOADED) AND WAS BACKING UP TO HOOKUP, HAD GOTTEN OUT TO CHECK LINEUP AND WHEN I GOT BACK IN TO BACKUP FURTHER THE BRAKE PEDAL WENT TO THE FLOOR AND GOT A "SERVICE BRAKE SYSTEM" WARNING ON THE GAUGES. UPON INVESTIGATION I FOUND ONE…
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HAD JUST DRIVEN 30 MILES ON BACKROADS TO MY PARENTS HOUSE TO PICKUP AN ENCLOSED RACE TRAILER (FULLY LOADED) AND WAS BACKING UP TO HOOKUP, HAD GOTTEN OUT TO CHECK LINEUP AND WHEN I GOT BACK IN TO BACKUP FURTHER THE BRAKE PEDAL WENT TO THE FLOOR AND GOT A "SERVICE BRAKE SYSTEM" WARNING ON THE GAUGES. UPON INVESTIGATION I FOUND ONE OF THE FRONT BRAKE LINES THAT RUN ON TOP OF THE FRAME RAIL IN THE ENGINE BAY THAT RUNS ON THE DRIVERS SIDE NEXT TO THE ENGINE HAD BURST AND THE LINES WERE RUSTED. I WOULD HATE TO WONDER WHAT WOULD OF HAPPENED IF THIS HAPPENED WHILE I WAS PULLING TRAILER ON COUNTRY BACKROADS AS I WAS GETTING READY TO DO......GM REALLY NEEDS TO ADDRESS THIS PROBLEM. *TR
BRAKE LINES COMPLETELY ROTTED BEYOND REPAIR, SO BAD THAT THEY CANNOT BE REMOVED FROM THE ABS UNIT, WHICH SHOULD NOT BE UNDERNEATH THE TRUCK, SO VULNERABLE TO CORROSION FROM SALT. THEY SHOULD HAVE BEEN STAINLESS LINES, OR ROUTED DIFFERENTLY. SAME WITH THE FUEL LINES. I WAS A DIE HARD CHEVY GUY, BUT THIS IS RIDICULOUS. SOOO MA…
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BRAKE LINES COMPLETELY ROTTED BEYOND REPAIR, SO BAD THAT THEY CANNOT BE REMOVED FROM THE ABS UNIT, WHICH SHOULD NOT BE UNDERNEATH THE TRUCK, SO VULNERABLE TO CORROSION FROM SALT. THEY SHOULD HAVE BEEN STAINLESS LINES, OR ROUTED DIFFERENTLY. SAME WITH THE FUEL LINES. I WAS A DIE HARD CHEVY GUY, BUT THIS IS RIDICULOUS. SOOO MANY PEOPLE HAVE ISSUES WITH THIS, GM NEEDS TO STEP UP. I CAN'T WAIT TO SELL THIS TRUCK AND BUY AN ANTIQUE. *TR
Official recalls
0No 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
3EA11001 · 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.