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2002 Chevrolet Silverado 2500

Owner reports · Recalls · Investigations

More warning signs than most Silverado 2500 years

Owner complaints for the 2002 Chevrolet Silverado 2500 are substantially higher than the model-year median of 81.

About this comparison →

When problems were reported

Mileage at the reported incident

307 reports with mileage · 44 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Service Brakes, Hydraulic. Review the 117 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes. Review the 88 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine And Engine Cooling. Review the 43 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

21 crash reports6 fire reports7 injury reports

What owners actually said

351 reports
158,000 miles · Feb 2, 2016
Fuel/propulsion SystemService Brakes

ALL MY BRAKE LINES ARE CORRODED/RUSTING OUT. ONE LINE ALREADY HAD TO BE REPLACED. VERY DANGEROUS. ALL MY FUEL INES ARE STARTING TO CORRODE AND APPEAR TO REQUIRE REPLACEMENT SOON.

NHTSA ODI #10823804

184,000 miles · Nov 30, 2015
Tires

TL* THE CONTACT OWNS A 2002 CHEVROLET SILVERADO 2500 HD EQUIPPED WITH KUMHO ROAD VENTURES A/T TIRS, SIZE 245/75 R16 (NA). WHILE DRIVING APPROXIMATELY 60 MPH, THERE WAS A VIBRATION COMING FROM THE REAR PASSENGER SIDE TIRE. THE CONTACT DECREASED THE SPEED TO 10 MPH AND THE REAR PASSENGER SIDE TIRE BLEW UP. THE TIRE WAS REPLACED WI…

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TL* THE CONTACT OWNS A 2002 CHEVROLET SILVERADO 2500 HD EQUIPPED WITH KUMHO ROAD VENTURES A/T TIRS, SIZE 245/75 R16 (NA). WHILE DRIVING APPROXIMATELY 60 MPH, THERE WAS A VIBRATION COMING FROM THE REAR PASSENGER SIDE TIRE. THE CONTACT DECREASED THE SPEED TO 10 MPH AND THE REAR PASSENGER SIDE TIRE BLEW UP. THE TIRE WAS REPLACED WITH A SPARE AND THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC. IT WAS DIAGNOSED THAT THE TREAD SEPARATED. THE TIRE WAS REPLACED. ALSO, WHILE DRIVING APPROXIMATELY 60 MPH, THE REAR DRIVER SIDE TIRE BLEW UP. THE TIRE WAS REPLACED WITH A SPARE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURES. THE APPROXIMATE VEHICLE FAILURE MILEAGE WAS 184,000 AND THE APPROXIMATE TIRE FAILURE MILEAGE WAS 14,000.

NHTSA ODI #10807471

134,000 miles · Nov 11, 2015
Fuel/propulsion System

MY COMPLAINT IS MORE OF A QUESTION. HOW CAN A RECALL HAVE A CUTOFF DEADLINE, ESPECIALLY WHEN THE ITEM RECALLED MAY OR MAY NOT BE BAD? THERE WAS A RECALL ON MY INJECTORS AND I NEVER NEW IT TILL THEY WENT BAD AND I TOOK IT TO DEALER TO FIX AND THEY SAID INJECTORS HAD BEEN RECALLED BUT RECALL EXPIRED. THEN, 13 MONTHS AFTER HAVI…

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MY COMPLAINT IS MORE OF A QUESTION. HOW CAN A RECALL HAVE A CUTOFF DEADLINE, ESPECIALLY WHEN THE ITEM RECALLED MAY OR MAY NOT BE BAD? THERE WAS A RECALL ON MY INJECTORS AND I NEVER NEW IT TILL THEY WENT BAD AND I TOOK IT TO DEALER TO FIX AND THEY SAID INJECTORS HAD BEEN RECALLED BUT RECALL EXPIRED. THEN, 13 MONTHS AFTER HAVING THEM REPLACED, 3 GO BAD AND YA'LL ONLY OFFER A 1 YEAR WARRANTY WHEN YOU REPLACE THEM, HOW CONVENIENT. YOU HAVE AN EXPIRATION ON A RECALL.

NHTSA ODI #10789727

Mileage unknown · Oct 16, 2015
Air Bags

ON THURSDAY, AUGUST 6, 2015 AT APPROXIMATELY 1:20 PM NATCHEZ RAILWAY EMPLOYEES [XXX] WERE ATTEMPTING TO START VEHICLE #1828 WHICH WAS BEING STORED ON THE GROUNDS OF THE NATCHEZ DEPOT. VEHICLE #1828 IS A 2002 CHEVROLET 2500 PICKUP TRUCK WITH VIN #[XXX] AND HAD BEEN DRIVEN FROM THE GRENADA RAILWAY APPROXIMATELY THREE WEEKS PRIO…

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ON THURSDAY, AUGUST 6, 2015 AT APPROXIMATELY 1:20 PM NATCHEZ RAILWAY EMPLOYEES [XXX] WERE ATTEMPTING TO START VEHICLE #1828 WHICH WAS BEING STORED ON THE GROUNDS OF THE NATCHEZ DEPOT. VEHICLE #1828 IS A 2002 CHEVROLET 2500 PICKUP TRUCK WITH VIN #[XXX] AND HAD BEEN DRIVEN FROM THE GRENADA RAILWAY APPROXIMATELY THREE WEEKS PRIOR. [XXX] WAS SITTING IN THE DRIVER'S SEAT AND THE BATTERY APPEARED TO BE DEAD. WHEN HE PULLED THE HOOD RELEASE LATCH, THE PASSENGER SIDE AIR BAG ACTIVATED WITH A LARGE BANG AND THE CAB OF THE TRUCK WAS FILLED WITH A WHITE POWDER. [XXX] SUFFERED A SLIGHT RINGING IN THE EARS FROM THE NOISE. A CHECK WITH THE GENERAL MOTORS WEBSITE INDICATES THIS VEHICLE IS NOT SUBJECT TO ANY RECALLS, ESPECIALLY FOR DEFECTIVE AIRBAGS. AT THE TIME OF THE INCIDENT, THE AIR TEMPERATURE WAS APPROXIMATELY 95⁰ F WITH 60% HUMIDITY. THE VEHICLE HAS BEEN PARKED FOR OVER TWO WEEKS WITH THE DOORS AND WINDOWS CLOSED. DAYTIME HIGH TEMPERATURES DURING THIS PERIOD HAVE BEEN IN THE 95⁰ TO 100⁰ RANGE. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI #10782935

56,000 miles · Oct 8, 2015
Service Brakes

STEEL BRAKE LINES TO ABS CONTROL AND OTHER STEEL BRAKE LINES RUSTED THROUGH AND LEAKING, MUST BE REPLACED BEFORE BRAKES FAIL.

NHTSA ODI #10780710

64,850 miles · Sep 9, 2015
Service Brakes

DRIVING TO PICK UP MY SON FROM WORK ON SIDE STREETS,TRAVELING ABOUT 25MPH WHEN MY BRAKE WENT TO THE FLOOR.ALMOST REAR ENDED CAR AT STOP SIGN. GOT OUT OF TRUCK AND FOUND LARGE SPOT UNDER MY TRUCK,BRAKE FLUID. HAD IT TOWED TO BRAKE SHOP AND MECHANIC INFORMED ME MY BRAKE LINES WERE RUSTING THOUGH AND NEEDED TO REPLACE ALL BRAKE LI…

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DRIVING TO PICK UP MY SON FROM WORK ON SIDE STREETS,TRAVELING ABOUT 25MPH WHEN MY BRAKE WENT TO THE FLOOR.ALMOST REAR ENDED CAR AT STOP SIGN. GOT OUT OF TRUCK AND FOUND LARGE SPOT UNDER MY TRUCK,BRAKE FLUID. HAD IT TOWED TO BRAKE SHOP AND MECHANIC INFORMED ME MY BRAKE LINES WERE RUSTING THOUGH AND NEEDED TO REPLACE ALL BRAKE LINES. ALSO TOLD ME HE HAS SEEN THIS WITH 3 OR 4 OTHER CHEVY TRUCKS LATELY. FOUND OTHER COMPLAINTS AFTER TELLING MY STORY. HEARD THIS IS A KNOWN PROBLEM WITH THESE TRUCKS..I BOUGHT THIS TRUCK NEW & HAVE HAD IT RUST PROOFED 12 TIMES. THANK YOU

NHTSA ODI #10762728

153,000 miles · Aug 19, 2015
Fuel/propulsion System

AFTER ARRIVING AT MY DESTINATION AT 9PM AS I EXITED TRUCK , I SMELLED DEISEL FUEL. TOOK A FLASHLIGHT AND LOOKED UNDER TRUCK AND SAW DIESEL DRIPPING OFF FRAME RAIL ON DRIVERS SIDE OF VEHICLE. I SPENT THE NEXT 5 HOURS AFFECTING A TEMPORARY FIX ON THE METAL FUEL LINE TO STOP THE LEAK OVERNIGHT. AS I RAN MY THUMB ALONG THE FUEL LINE…

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AFTER ARRIVING AT MY DESTINATION AT 9PM AS I EXITED TRUCK , I SMELLED DEISEL FUEL. TOOK A FLASHLIGHT AND LOOKED UNDER TRUCK AND SAW DIESEL DRIPPING OFF FRAME RAIL ON DRIVERS SIDE OF VEHICLE. I SPENT THE NEXT 5 HOURS AFFECTING A TEMPORARY FIX ON THE METAL FUEL LINE TO STOP THE LEAK OVERNIGHT. AS I RAN MY THUMB ALONG THE FUEL LINE IN AN EFFORT TO ISOLATE THE EXACT SPOT OF THE LEAK, THE LEAK WENT FROM A DRIP, DRIP, ETC TO A PINHOLE STREAM. THERE WAS ABSOLUTELY NO DENT FROM EXTERNAL CONTACT OF ANY KIND. I AM THE ORIGINAL OWNER OF THIS VEHICLE. IT HAS BEEN WELL MAINTAINED AND WE DO NOT LIVE IN AN AREA OF MUCH WINTER WEATHER ( SALT CORROSION ). THE NEXT DAY AFTER A 3 MILE WALK TO PURCHASE SOME HOSE REPAIR CLAMPS, I IMPROVISED A STURDY PATCH WHICH ALLOWED ME TO DRIVE THE VEHICLE HOME MORE THAN 2 HOURS AWAY. I HAVE CONTACTED CHEVROLET AND WILL BE TAKING THE TRUCK TO A DEALER MONDAY 7/24. THE REP I SPOKE WITH AT CHEVY SPENT MOST OF THE CONVERSATION TELLING ME THAT BECAUSE OF THE AGE AND MILEAGE OF THE VEHICLE THAT THE REPAIRS WERE MY RESPONSIBILITY. THAT'S FINE BUT I TOTALLY DISAGREE WITH THEM. THIS IS NOT A MAINTENANCE ISSUE. IT IS A DEFECTIVE OR POORLY DESIGNED PART THAT COULD EASILY RESULT IN FIRE, ACCIDENTS AND EVEN BODILY HARM OR THE LOSS OF LIFE. THERE IS ABSOLUTELY NO EXCUSE FOR A LEAKING METAL FUEL LINE THAT HAS NEVER BEEN DAMAGED IN ANY WAY AT ALL. FROM THE INTERNET FORUMS FOR DURAMAX OWNERS I SEE THAT THIS IS NOT AN UNCOMMON PROBLEM. I ASSURE THERE ARE MANY LESS THAN SAFE IMPROVISED FIXES ON THESE LOUSY FUEL LINES ON THE ROADS AS WE SPEAK BECAUSE GM IS NOT ACCEPTING RESPONSIBILITY FOR THIS PROBLEM. THIS IS SHAMEFUL AND INCREDIBLY DANGEROUS. I ALSO UNDERSTAND THERE HAVE BEEN ISSUES WITH THE METAL BRAKE LINES AS WELL. I LIKE MY TRUCK A GREAT DEAL, HOWEVER THIS ISSUE NEEDS TO BE RESOLVED. THERE ARE ALOT UNSUSPECTING FOLKS DRIVING AROUND DANGEROUSLY. THANKS

NHTSA ODI #10749735

84,425 miles · Jul 29, 2015
Service Brakes

WHILE BACKING OUT OF MY DRIVEWAY I ATTEMPTED TO STOP DUE TO TRAFFIC TRAVELING ALONG THE ROUTE I WAS ENTERING. WHEN I APPLIED THE BRAKE THE PEDDLE WENT COMPLETELY TO THE FLOOR. LUCKILY I WAS ABLE TO STOP WITH THE EMERGENCY BRAKE IN TIME TO AVOID AN ACCIDENT WITH A TRASH TRUCK THAT WAS TRAVELING ALONG THAT ROUTE. USING THE EME…

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WHILE BACKING OUT OF MY DRIVEWAY I ATTEMPTED TO STOP DUE TO TRAFFIC TRAVELING ALONG THE ROUTE I WAS ENTERING. WHEN I APPLIED THE BRAKE THE PEDDLE WENT COMPLETELY TO THE FLOOR. LUCKILY I WAS ABLE TO STOP WITH THE EMERGENCY BRAKE IN TIME TO AVOID AN ACCIDENT WITH A TRASH TRUCK THAT WAS TRAVELING ALONG THAT ROUTE. USING THE EMERGENCY BRAKE I WAS ABLE TO PULL THE VEHICLE BACK INTO MY DRIVEWAY SAFELY AND FOUND THAT THE BRAKE LINE WAS CORRODED AND WAS LEAKING JUST UNDER THE DRIVERS SIDE DOOR. MY VEHICLE IS WELL MAINTAIN AND I AM OFTEN COMPLEMENTED FOR THE CARE I TAKE OF BOTH IT'S APPEARANCE AND MAINTENANCE. THE IS NO OTHER AREA OF THIS VEHICLE THAT IS RUSTED AND THE UNDERNEATH OF THIS VEHICLE IS IN VERY GOOD SHAPE. I AM THE ORIGINAL OWNER OF THIS VEHICLE AND IT HAS NOT BEEN SUBJECT TO ANY TYPE OF EXCESS WEATHER CONDITIONS. THERE IS NO REASON THESE LINES SHOULD HAVE FAILED LIKE THIS. I HAVE BEEN AN ASE CERTIFIED AUTO TECH FOR BRAKES AND CAN TELL YOU THAT IS IS NOT COMMON TO CHECK THE LINES OVER THE TOP OF THE FRAME DURING ROUTINE BRAKE INSPECTIONS AND MAINTENANCE, ONLY TO CHECK FOR SIGNS OF LEAKS IN NORMAL LINE LOCATIONS AND SOFT LINES, CALIPERS AND OTHER HARDWARE RELATED TO THE WHEEL AREA.

NHTSA ODI #10744703

270,000 miles · Jun 14, 2015
Service Brakes

CORROSION IN THE BRAKE LINES CAUSED A BLOWOUT OF THE BRAKE LINES AND FAILURE OF THE BRAKES.

NHTSA ODI #10725143

247,433 miles · May 14, 2015
EngineLatches/locks/linkagesSeat BeltsFire

TL* THE CONTACT OWNED A 2002 CHEVROLET SILVERADO 2500 HD. WHILE DRIVING APPROXIMATELY 75 MPH, A MESSAGE INDICATING THAT THE ENGINE OVERHEATED DISPLAYED AND SMOKE APPEARED UNDER THE HOOD OF THE VEHICLE. THE FLAMES QUICKLY SPREAD TO THE CABIN OF THE VEHICLE. WHILE THE FLAMES WERE INSIDE THE CABIN, THE CONTACT ATTEMPTED TO EXIT THE…

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TL* THE CONTACT OWNED A 2002 CHEVROLET SILVERADO 2500 HD. WHILE DRIVING APPROXIMATELY 75 MPH, A MESSAGE INDICATING THAT THE ENGINE OVERHEATED DISPLAYED AND SMOKE APPEARED UNDER THE HOOD OF THE VEHICLE. THE FLAMES QUICKLY SPREAD TO THE CABIN OF THE VEHICLE. WHILE THE FLAMES WERE INSIDE THE CABIN, THE CONTACT ATTEMPTED TO EXIT THE VEHICLE BUT THE DRIVER SIDE SEAT BELT WOULD NOT IMMEDIATELY UNLOCK. THE SEAT BELT FINALLY UNLOCKED, BUT THE DRIVER SIDE DOOR WOULD NOT UNLOCK. THE DOOR EVENTUALLY UNLOCKED AND THE CONTACT WAS ABLE TO EXIT THE VEHICLE. THE FIRE DEPARTMENT WAS CALLED TO THE SCENE TO EXTINGUISH THE FLAMES. THE VEHICLE WAS DESTROYED. THERE WERE NO INJURIES. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 247,433.

NHTSA ODI #10716521

Official recalls

1

01V220000 · Interior Lighting

Jun 26, 2001

VEHICLE DESCRIPTION: CERTAIN PICKUP TRUCKS EQUIPPED WITH 6.6L DIESEL ENGINES FAIL TO COMPLY WITH REQUIREMENTS OF FMVSS NO. 105, "HYDRAULIC AND ELECTRIC BRAKE SYSTEMS." THESE VEHICLES HAVE A BRAKE SYSTEM WARNING LIGHT IN THE INSTRUMENT CLUSTER THAT MAY NOT ILLUMINATE WHEN THE BRAKE FLUID IS LOW. IN ADDITION, WHEN THE BRAKE FLUID IS LOW, THE VEHICLE MAY NOT MEET THE PARTIAL SYSTEM REQUIREMENTS OF FMVSS NO. 105.

Consequence & remedy

Consequence: THESE CONDITIONS COULD RESULT IN REDUCED BRAKING CAPABILITY, WHICH COULD LEAD TO A CRASH.

Remedy: DEALERS WILL CHANGE THE LOCATION OF A WIRE CONNECTION IN THE UNDERHOOD BUSSED ELECTRICAL CENTER. OWNER NOTIFICATION BEGAN JULY 9, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT CHEVROLET AT 1-800-222-1020 OR GMC AT 1-800-462-8782.

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

4

EA07013 · Trailer Hitch Receiver Failure

Opened Sep 14, 2007 · Closed Sep 12, 2008

Status: closed (inferred from source dates) · Trailer Hitches

COMPLAINT REPORTS ALLEGE POOR WELD QUALITY AND/OR BENDING OF THE SUBJECT VEHICLE ORIGINAL EQUIPMENT TRAILER HITCH RECEIVER.THE AGENCY'S INVESTIGATION INCLUDED ANALYSIS OF MANUFACTURER AND AGENCY INCIDENT REPORTS, REVIEW OF POLICE REPORTS, ANALYSIS OF THE AGENCY'S FATAL ANALYSIS REPORTING SYSTEM, A VEHICLE OWNER SURVEY, INSPECTION OF TOW VEHICLES/HITCHES AND ANALYSIS OF FAILED PARTS.INCIDENTS OF WELD FAILURE WERE RARE AND ASSOCIATED WITH VERY LOW-SPEED DRIVING (TURNING, BACKING AND SUDDEN STOPPING).INCIDENTS OF BENDING WERE ASSOCIATED WITH IMPROPER TRAILER HITCH ADJUSTMENT OR OVERLOADING. A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.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 THIS ISSUE AND RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE DOCUMENT SEARCH FILE FOR ADDITION INFORMATION.

PE07025 · Trailer Hitch Receiver Failure

Opened May 14, 2007 · Closed Sep 14, 2007

Status: closed (inferred from source dates) · Trailer Hitches

GM PROVIDED ADDITIONAL DATA REGARDING ALLEGATIONS OF FAILURE OF THE TRAILER HITCH.ODI REVIEWED THAT AS WELL AS OTHER DATA PROVIDED BY PEER MANUFACTURERS.BASED ON OUR REVIEW, ODI FINDS THE NEED TO FURTHER INVESTIGATE THIS ISSUE.THIS PRELIMINARY EVALUATION IS UPGRADED TO AN ENGINEERING ANALYSIS (EA07-013) FOR FURTHER ASSESSMENT AND STUDY OF THIS ISSUE.

EA04012 · Hydraulic Pump Failres

Opened Apr 30, 2004 · Closed Feb 28, 2005

Status: closed (inferred from source dates) · Service Brakes, Hydraulic:power Assist; Steering:hydraulic Power Assist System

GM IS CONDUCTING A RECALL ON ALL SUBJECT VEHICLES BUILD BETWEEN MAY 1999 AND OCTOBER 14, 1999.SIGNIFICANT CHANGES WERE INCORPORATED INTO PRODUCTION IN EARLY OCTOBER 1999, AND VEHICLES BUILT AFTER THAT DATE HAVE LOWER WARRANTY FAILURE RATES.THE COMPLAINT AND WARRANTY DATA APPEAR TO SUPPORT THE EFFECTIVENESS OF THESE CHANGES. GM MADE ADDITIONAL CHANGES IN NOVEMBER 1999, FEBRUARY 2000, MAY 2001, AND FEBRUARY 2004.ODI WILL CONTINUE TO MONITOR THIS PROBLEM AND WILL TAKE FURTHER ACTION, IF WARRANTED, IN THE FUTURE.FOR FURTHER TECHNICAL DETAILS SEE THE ATTACHED ENGINEERING ANALYSIS REPORT.

Additional source detail variants (2)

Service Brakes, Hydraulic:power Assist

GM IS CONDUCTING A RECALL ON ALL SUBJECT VEHICLES BUILD BETWEEN MAY 1999 AND OCTOBER 14, 1999.SIGNIFICANT CHANGES WERE INCORPORATED INTO PRODUCTION IN EARLY OCTOBER 1999, AND VEHICLES BUILT AFTER THAT DATE HAVE LOWER WARRANTY FAILURE RATES.THE COMPLAINT AND WARRANTY DATA APPEAR TO SUPPORT THE EFFECTIVENESS OF THESE CHANGES. GM MADE ADDITIONAL CHANGES IN NOVEMBER 1999, FEBRUARY 2000, MAY 2001, AND FEBRUARY 2004.ODI WILL CONTINUE TO MONITOR THIS PROBLEM AND WILL TAKE FURTHER ACTION, IF WARRANTED, IN THE FUTURE.FOR FURTHER TECHNICAL DETAILS SEE THE ATTACHED ENGINEERING ANALYSIS REPORT.

Steering:hydraulic Power Assist System

GM IS CONDUCTING A RECALL ON ALL SUBJECT VEHICLES BUILD BETWEEN MAY 1999 AND OCTOBER 14, 1999.SIGNIFICANT CHANGES WERE INCORPORATED INTO PRODUCTION IN EARLY OCTOBER 1999, AND VEHICLES BUILT AFTER THAT DATE HAVE LOWER WARRANTY FAILURE RATES.THE COMPLAINT AND WARRANTY DATA APPEAR TO SUPPORT THE EFFECTIVENESS OF THESE CHANGES. GM MADE ADDITIONAL CHANGES IN NOVEMBER 1999, FEBRUARY 2000, MAY 2001, AND FEBRUARY 2004.ODI WILL CONTINUE TO MONITOR THIS PROBLEM AND WILL TAKE FURTHER ACTION, IF WARRANTED, IN THE FUTURE.FOR FURTHER TECHNICAL DETAILS SEE THE ATTACHED ENGINEERING ANALYSIS REPORT.

PE04004 · Hydraulic Pump Shaft Failures

Opened Jan 8, 2004 · Closed Apr 30, 2004

Status: closed (inferred from source dates) · Service Brakes, Hydraulic; Service Brakes, Hydraulic:power Assist; Service Brakes, Hydraulic:power Assist:hydraulic; Steering:hydraulic Power Assist System; Steering:hydraulic Power Assist:pump

THE PRELIMINARY EVAULATION IS BEING UPGRADED.DURING THE EA ODI WILL LIMITITS INVESTIGATION TO ONLY THOSE VEHICLES EQUIPPED WITH A HYDRO-BOOST SYSTEM, WHICH PROVIDES POWER ASSIST TO THE BRAKING AND STEERING SYTEMS.VACCUUM BRAKE BOOSTER VEHICLES ARE EXCLUDED.ODI HASEXPANDED THE SCOPE OF THE EA TO INCLUDE MODEL YEARS2003 AND 2004, ASDURING THE PE, ODI LEARNED THAT THE HYDROBOAST PUMPS WERE MODIFIED IN FEBRAURY 2004.THEREFORE,ODI HAS EXPANDED THE SCOPE TO INCLUDE THE ADDITIONAL MODEL YEARS.ODI'S IS CONCERNED BECAUSE THISISA SUDDEN FAILURE THAT AFFECTS TWO CRITICAL SYSTEMS OF THE VEHICLE, BRAKES AND STEERING, AT THE SAME TIME.THE ABILITY OF THE OPERATOR TO HANDLE THE DUAL FAILURES IS A CONCERN. FURTHER, THESE VEHICLES TEND TO BE WORK VEHICLES, WITH SOME OVER 10,000 POUNDS GVWR AND MANY EQUIPPED TO PULL LARGE TRAILERS.DUAL FAILURES OF HEAVILY LOADED VEHICLES AND VEHICLES PULLING TRAILERS FURTHER INCREASES THE SAFETY RISK.ODI PLANS TO CONDUCT TESTING TO QUANTIFY THE BRAKING AND STEERING PERFORMANCE DEGRADATION AND THE IMPACT ON SAFE VEHICLE CONTROL, WHEN A HYDROBOAST PUMP FAILS.

Additional source detail variants (5)

Service Brakes, Hydraulic

THE PRELIMINARY EVAULATION IS BEING UPGRADED.DURING THE EA ODI WILL LIMITITS INVESTIGATION TO ONLY THOSE VEHICLES EQUIPPED WITH A HYDRO-BOOST SYSTEM, WHICH PROVIDES POWER ASSIST TO THE BRAKING AND STEERING SYTEMS.VACCUUM BRAKE BOOSTER VEHICLES ARE EXCLUDED.ODI HASEXPANDED THE SCOPE OF THE EA TO INCLUDE MODEL YEARS2003 AND 2004, ASDURING THE PE, ODI LEARNED THAT THE HYDROBOAST PUMPS WERE MODIFIED IN FEBRAURY 2004.THEREFORE,ODI HAS EXPANDED THE SCOPE TO INCLUDE THE ADDITIONAL MODEL YEARS.ODI'S IS CONCERNED BECAUSE THISISA SUDDEN FAILURE THAT AFFECTS TWO CRITICAL SYSTEMS OF THE VEHICLE, BRAKES AND STEERING, AT THE SAME TIME.THE ABILITY OF THE OPERATOR TO HANDLE THE DUAL FAILURES IS A CONCERN. FURTHER, THESE VEHICLES TEND TO BE WORK VEHICLES, WITH SOME OVER 10,000 POUNDS GVWR AND MANY EQUIPPED TO PULL LARGE TRAILERS.DUAL FAILURES OF HEAVILY LOADED VEHICLES AND VEHICLES PULLING TRAILERS FURTHER INCREASES THE SAFETY RISK.ODI PLANS TO CONDUCT TESTING TO QUANTIFY THE BRAKING AND STEERING PERFORMANCE DEGRADATION AND THE IMPACT ON SAFE VEHICLE CONTROL, WHEN A HYDROBOAST PUMP FAILS.

Service Brakes, Hydraulic:power Assist

THE PRELIMINARY EVAULATION IS BEING UPGRADED.DURING THE EA ODI WILL LIMITITS INVESTIGATION TO ONLY THOSE VEHICLES EQUIPPED WITH A HYDRO-BOOST SYSTEM, WHICH PROVIDES POWER ASSIST TO THE BRAKING AND STEERING SYTEMS.VACCUUM BRAKE BOOSTER VEHICLES ARE EXCLUDED.ODI HASEXPANDED THE SCOPE OF THE EA TO INCLUDE MODEL YEARS2003 AND 2004, ASDURING THE PE, ODI LEARNED THAT THE HYDROBOAST PUMPS WERE MODIFIED IN FEBRAURY 2004.THEREFORE,ODI HAS EXPANDED THE SCOPE TO INCLUDE THE ADDITIONAL MODEL YEARS.ODI'S IS CONCERNED BECAUSE THISISA SUDDEN FAILURE THAT AFFECTS TWO CRITICAL SYSTEMS OF THE VEHICLE, BRAKES AND STEERING, AT THE SAME TIME.THE ABILITY OF THE OPERATOR TO HANDLE THE DUAL FAILURES IS A CONCERN. FURTHER, THESE VEHICLES TEND TO BE WORK VEHICLES, WITH SOME OVER 10,000 POUNDS GVWR AND MANY EQUIPPED TO PULL LARGE TRAILERS.DUAL FAILURES OF HEAVILY LOADED VEHICLES AND VEHICLES PULLING TRAILERS FURTHER INCREASES THE SAFETY RISK.ODI PLANS TO CONDUCT TESTING TO QUANTIFY THE BRAKING AND STEERING PERFORMANCE DEGRADATION AND THE IMPACT ON SAFE VEHICLE CONTROL, WHEN A HYDROBOAST PUMP FAILS.

Service Brakes, Hydraulic:power Assist:hydraulic

THE PRELIMINARY EVAULATION IS BEING UPGRADED.DURING THE EA ODI WILL LIMITITS INVESTIGATION TO ONLY THOSE VEHICLES EQUIPPED WITH A HYDRO-BOOST SYSTEM, WHICH PROVIDES POWER ASSIST TO THE BRAKING AND STEERING SYTEMS.VACCUUM BRAKE BOOSTER VEHICLES ARE EXCLUDED.ODI HASEXPANDED THE SCOPE OF THE EA TO INCLUDE MODEL YEARS2003 AND 2004, ASDURING THE PE, ODI LEARNED THAT THE HYDROBOAST PUMPS WERE MODIFIED IN FEBRAURY 2004.THEREFORE,ODI HAS EXPANDED THE SCOPE TO INCLUDE THE ADDITIONAL MODEL YEARS.ODI'S IS CONCERNED BECAUSE THISISA SUDDEN FAILURE THAT AFFECTS TWO CRITICAL SYSTEMS OF THE VEHICLE, BRAKES AND STEERING, AT THE SAME TIME.THE ABILITY OF THE OPERATOR TO HANDLE THE DUAL FAILURES IS A CONCERN. FURTHER, THESE VEHICLES TEND TO BE WORK VEHICLES, WITH SOME OVER 10,000 POUNDS GVWR AND MANY EQUIPPED TO PULL LARGE TRAILERS.DUAL FAILURES OF HEAVILY LOADED VEHICLES AND VEHICLES PULLING TRAILERS FURTHER INCREASES THE SAFETY RISK.ODI PLANS TO CONDUCT TESTING TO QUANTIFY THE BRAKING AND STEERING PERFORMANCE DEGRADATION AND THE IMPACT ON SAFE VEHICLE CONTROL, WHEN A HYDROBOAST PUMP FAILS.

Steering:hydraulic Power Assist:pump

THE PRELIMINARY EVAULATION IS BEING UPGRADED.DURING THE EA ODI WILL LIMITITS INVESTIGATION TO ONLY THOSE VEHICLES EQUIPPED WITH A HYDRO-BOOST SYSTEM, WHICH PROVIDES POWER ASSIST TO THE BRAKING AND STEERING SYTEMS.VACCUUM BRAKE BOOSTER VEHICLES ARE EXCLUDED.ODI HASEXPANDED THE SCOPE OF THE EA TO INCLUDE MODEL YEARS2003 AND 2004, ASDURING THE PE, ODI LEARNED THAT THE HYDROBOAST PUMPS WERE MODIFIED IN FEBRAURY 2004.THEREFORE,ODI HAS EXPANDED THE SCOPE TO INCLUDE THE ADDITIONAL MODEL YEARS.ODI'S IS CONCERNED BECAUSE THISISA SUDDEN FAILURE THAT AFFECTS TWO CRITICAL SYSTEMS OF THE VEHICLE, BRAKES AND STEERING, AT THE SAME TIME.THE ABILITY OF THE OPERATOR TO HANDLE THE DUAL FAILURES IS A CONCERN. FURTHER, THESE VEHICLES TEND TO BE WORK VEHICLES, WITH SOME OVER 10,000 POUNDS GVWR AND MANY EQUIPPED TO PULL LARGE TRAILERS.DUAL FAILURES OF HEAVILY LOADED VEHICLES AND VEHICLES PULLING TRAILERS FURTHER INCREASES THE SAFETY RISK.ODI PLANS TO CONDUCT TESTING TO QUANTIFY THE BRAKING AND STEERING PERFORMANCE DEGRADATION AND THE IMPACT ON SAFE VEHICLE CONTROL, WHEN A HYDROBOAST PUMP FAILS.

Steering:hydraulic Power Assist System

THE PRELIMINARY EVAULATION IS BEING UPGRADED.DURING THE EA ODI WILL LIMITITS INVESTIGATION TO ONLY THOSE VEHICLES EQUIPPED WITH A HYDRO-BOOST SYSTEM, WHICH PROVIDES POWER ASSIST TO THE BRAKING AND STEERING SYTEMS.VACCUUM BRAKE BOOSTER VEHICLES ARE EXCLUDED.ODI HASEXPANDED THE SCOPE OF THE EA TO INCLUDE MODEL YEARS2003 AND 2004, ASDURING THE PE, ODI LEARNED THAT THE HYDROBOAST PUMPS WERE MODIFIED IN FEBRAURY 2004.THEREFORE,ODI HAS EXPANDED THE SCOPE TO INCLUDE THE ADDITIONAL MODEL YEARS.ODI'S IS CONCERNED BECAUSE THISISA SUDDEN FAILURE THAT AFFECTS TWO CRITICAL SYSTEMS OF THE VEHICLE, BRAKES AND STEERING, AT THE SAME TIME.THE ABILITY OF THE OPERATOR TO HANDLE THE DUAL FAILURES IS A CONCERN. FURTHER, THESE VEHICLES TEND TO BE WORK VEHICLES, WITH SOME OVER 10,000 POUNDS GVWR AND MANY EQUIPPED TO PULL LARGE TRAILERS.DUAL FAILURES OF HEAVILY LOADED VEHICLES AND VEHICLES PULLING TRAILERS FURTHER INCREASES THE SAFETY RISK.ODI PLANS TO CONDUCT TESTING TO QUANTIFY THE BRAKING AND STEERING PERFORMANCE DEGRADATION AND THE IMPACT ON SAFE VEHICLE CONTROL, WHEN A HYDROBOAST PUMP FAILS.