Illustration2002 CHEVROLET TAHOE BROKEN BRAKE LINE. CONSUMER STATES THAT THE DEALER STATED THE BRAKE LINE BROKE DUE TO RUST. CONSUMER WAS ALSO TOLD IT BROKE DUE TO HYDRAULIC PRESSURE. VEHICLE WAS AT DEALER THE DAY BEFORE WITH NOT PROBLEMS. *KB
2002 Chevrolet Tahoe
Owner reports · Recalls · Investigations
Similar to other model years
Owner complaints for the 2002 Chevrolet Tahoe do not stand out strongly from the model-year median of 246.
About this comparison →How this year compares
Owner complaints by model year
Compare all Tahoe 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
410–25K
5825–50K
6350–75K
4775–100K
69100–150K
61150K+
339 reports with mileage · 110 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 90 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Service Brakes, Hydraulic. Review the 68 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Steering. Review the 40 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
42 crash reports8 fire reports32 injury reports
Service Brakes, Hydraulic complaints
68 reports2002 CHEVROLET TAHOE WITH DEFECTIVE BRAKE ROTORS. CONSUMER STATED THAT THE BRAKES BARELY STOPPED THE VEHICLE. UPON INSPECTION MECHANIC DETERMINED THE PADS WERE FINE AND FOUND THE ROTORS RUSTED AND FELL APART ON THE INSIDE. *KB
AT SLOW SPEEDS AND USUALLY UNDER DAMP CONDITIONS, THE ANTILOCK BRAKES ON MY 2002 TAHOE TAKE HOLD WHEN I AM STOPPING AND ALLOW THE CAR TO CONTINUE AT LEAST 10 FEET AHEAD INTO THE ROADWAY WITH NO STOPPING THE VEHICLE. CONDITION CAN EASILY CAUSE ACCIDENTS AS I HAVE HAD NUMEROUS CLOSE CALLS. NO CODES APPEAR ON AUTO COMPUTER WHEN I…
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AT SLOW SPEEDS AND USUALLY UNDER DAMP CONDITIONS, THE ANTILOCK BRAKES ON MY 2002 TAHOE TAKE HOLD WHEN I AM STOPPING AND ALLOW THE CAR TO CONTINUE AT LEAST 10 FEET AHEAD INTO THE ROADWAY WITH NO STOPPING THE VEHICLE. CONDITION CAN EASILY CAUSE ACCIDENTS AS I HAVE HAD NUMEROUS CLOSE CALLS. NO CODES APPEAR ON AUTO COMPUTER WHEN I TAKE IT TO THE DEALER. THERE IS A RECALL #05V379000 THAT EXACTLY EXPLAINS THE SITUATION BUT SINCE MY VIN# DOES NOT SEEM TO BE INCLUDED IN THE RECALL, CHEVROLET WILL DO NOTHING ABOUT THE SITUATION WHICH HAS BEEN ONGOING SINCE MARCH OF 2004. I HAVE HAD THE VEHICLE IN MANY TIMES AND JUST DISCOVERED ON MY OWN THAT SEPT 22, 2005 THIS RECALL CAME OUT. I HAD THE VEHICLE TO SIGEL CHEVROLET FOR THE THIRD TIME ON SEPT 14, 2005 AND WAS ONCE AGAIN TOLD THAT THE BRAKES WERE FUNCTIONING PROPERLY. THEY COULD NOT DUPLICATE THE SITUATION SO IT MUST NOT BE HAPPENING. WHEN I NEARLY HIT OUR GARAGE DOOR ON 11/16/2007 WITH MY HUSBAND AS A PASSENGER IN THE CAR, I WENT LOOKING FOR ANY RECALL INFORMATION AND FOUND THAT THERE WAS ONE OUT THERE BUT THE DEALER TOLD ME IT DID NOT APPLY TO ME AND SO DID CHEVROLET CUSTOMER SERVICE WHO HAS A FILE ON THIS NOW (#71-578554426) BUT THEY STILL DENIED THERE IS ANYTHING THEY SHOULD BE DOING. ON 11/30/07 I TOOK THE VEHICLE IN AGAIN FOR A DIAGNOSIS AS SUGGESTED BY CHEVROLET CUSTOMER SERVICE AND AGAIN THEY FOUND NOTHING BUT I REQUESTED THE DEALER PERFORM THE REMEDY THAT IS EXPLAINED ON THE RECALL NOTICE AND I PAID FOR THAT SERVICE TO BE DONE. *TR
IN FEBRUARY 2004, I PURCHASED A USED 2002 CHEVROLET. IN JUNE 2004 THE VEHICLE'S ELECTRONIC BRAKE CONTROL MODULE FAILED AND WAS REPLACED BY MY LOCAL CHEVROLET DEALER. AT THE TIME OF THE REPAIR THE VEHICLE HAD 52, 000 MILES. ON FEBRUARY 15, 2007 THE SAME PART FAILED AGAIN. THE VEHICLE NOW HAS 102,000 MILES. THE ELECTRONIC BRAKE CO…
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IN FEBRUARY 2004, I PURCHASED A USED 2002 CHEVROLET. IN JUNE 2004 THE VEHICLE'S ELECTRONIC BRAKE CONTROL MODULE FAILED AND WAS REPLACED BY MY LOCAL CHEVROLET DEALER. AT THE TIME OF THE REPAIR THE VEHICLE HAD 52, 000 MILES. ON FEBRUARY 15, 2007 THE SAME PART FAILED AGAIN. THE VEHICLE NOW HAS 102,000 MILES. THE ELECTRONIC BRAKE CONTROL MODULE IS A NON-WEAR ITEM. I CONTACTED CHEVROLET TO INQUIRE ABOUT A RECALL ON THIS ITEM. NO RECALL EXIST HOWEVER THERE HAVE BEEN TECHNICAL SERVICE BULLETINS ISSUE CONCERNING THIS ITEM. I WAS TOLD BY CHEVROLET AND THE REPAIR FACILITY THAT BECAUSE MY VEHICLE NOW HAS MORE THAN 100,000 MILES I WOULD HAVE TO REPLACE THE ITEM AT MY EXPENSE. *JB
PROBLEM WITH BRAKING SYSTEM OF MY 2002 CHEVROLET TAHOE LS 1500. WITHIN A YEAR OF PURCHASING THE TAHOE THE BRAKING SYSTEM BEGAN TO ACT STRANGELY. FOR EXAMPLE, WHILE DRIVING MY DAUGHTER TO PRESCHOOL IN SAN FRANCISCO, CA. THERE IS HILL I DRIVE DOWN WITH A STOP SIGN AT THE BOTTOM. THERE IS A BUMP IN THE ROAD APPROX. 30 FEET FROM …
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PROBLEM WITH BRAKING SYSTEM OF MY 2002 CHEVROLET TAHOE LS 1500. WITHIN A YEAR OF PURCHASING THE TAHOE THE BRAKING SYSTEM BEGAN TO ACT STRANGELY. FOR EXAMPLE, WHILE DRIVING MY DAUGHTER TO PRESCHOOL IN SAN FRANCISCO, CA. THERE IS HILL I DRIVE DOWN WITH A STOP SIGN AT THE BOTTOM. THERE IS A BUMP IN THE ROAD APPROX. 30 FEET FROM THE STOP SIGN - ALMOST EVERY TIME I HIT THIS BUMP, WITH THE BRAKE ALREADY ENGAGED - THE BRAKE SYSTEM "DISENGAGES" WHEN I HIT THE BUMP AND I HAVE TO FRANTICALLY PUSH THE BRAKE AGAIN TO TRY TO STOP THE VEHICLE. A FEW TIMES I HAVE ENDED UP IN THE MIDDLE OF THE STREET BEFORE THE BRAKE ENGAGES. IT IS ONLY PURE LUCK THAT NO ONE HAS BEEN HIT OR KILLED. I KNOW NOW TO AVOID THIS STREET , BUT IT HAPPENS APPROX. 5 TO 10 TIMES A MONTH AT DIFFERENT TIMES, WEATHER CONDITIONS, ROAD SURFACES, ETC. I AM UTTERLY PARANOID ABOUT THIS AND DRIVE VERY CAUTIOUSLY - IT IS ONLY FOR THAT REASON THAT I HAVEN'T BEEN IN AN ACCIDENT. IN MAY OF 2005 I FINALLY INSISTED ON REPLACING THE BRAKES AT MY OWN EXPENSE, YET THIS HASN'T SOLVED THE PROBLEM. THE EMERGENCY BRAKE PROBLEM IS HORRIBLE. THIS STARTED AS SOON AS THE BRAKES WERE REPLACED IN MAY 2005- IT STARTED STICKING ONCE IN A WHILE AND WORKED ITS WAY UP TO A FEW TIMES A DAY. THE EMERGENCY BRAKE WAS REPLACED IN APRIL OF 2006 YET THIS SOLVED NOTHING, THE PROBLEM IS JUST AS BAD IF NOT WORSE NOW. THE CHEVROLET DEALER I HAVE BEEN WORKING WITH, PUTNAM CHEVROLET IN BURLINGAME, CA., ACTS AS IF I AM DRIVING THE VEHICLE LIKE A MANIAC AND IT IS ALL MY FAULT. FOR THE FIRST TIME TONIGHT, IN A TERRIBLE CASE OF FRUSTRATION, I TURNED TO THE INTERNET TO INVESTIGATE AND WAS STUNNED BY WHAT I DISCOVERED-A PROBLEM WITH ABS BRAKES FOR THIS VEHICLE THAT HAS BEEN RECALLED IN ONLY 20 STATES, AND A KNOWN DEFECT WITH THE EMERGENCY BRAKE THAT HAS RESULTED IN BULLETINS TO THE DEALER BUT NO RECALL. FIVE OTHER PEOPLE I KNOW HAVE EXPERIENCED THE SAME TYPE OF PROBLEMS WITH EITHER A TAHOE OR YUKON - HUGE PROBLEM AND NEEDS TO BE INVESTIGATED. *NM
DT*: THE CONTACT STATED THAT IN 2005 THE FRONT END WAS REPLACED DUE TO A LOCK UP WHILE MAKING A TURN. THE DEALER DETERMINED IT WAS DUE TO CATASTROPHIC FAILURE. ON 06/01/06, THERE WERE PROBLEMS WITH THE FRONT ABS SENSOR. THE BRAKES WOULD NOT WORK PROPERLY AT A VERY LOW SPEED. THE VEHICLE WAS TAKEN TO THE SERVICE DEALER ON 06/16/2…
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DT*: THE CONTACT STATED THAT IN 2005 THE FRONT END WAS REPLACED DUE TO A LOCK UP WHILE MAKING A TURN. THE DEALER DETERMINED IT WAS DUE TO CATASTROPHIC FAILURE. ON 06/01/06, THERE WERE PROBLEMS WITH THE FRONT ABS SENSOR. THE BRAKES WOULD NOT WORK PROPERLY AT A VERY LOW SPEED. THE VEHICLE WAS TAKEN TO THE SERVICE DEALER ON 06/16/2006 WHERE THE DEALER DETERMINED THIS ABS SENSOR FAILURE WAS RECALLED AND THE REMEDY REPAIR WAS ALREADY PROCESS ON THE VEHICLE. THE HUB WAS REFERENCED AS THE CAUSE OF THE ABS FAILURE BUT WAS NOT INCLUDED IN THE RECALL. THE VEHICLE CAN NOT BE DRIVEN BECAUSE IT IS UNSAFE. THE MANUFACTURER ALERTED THE CONTACT THE VEHICLE WOULD NOT BE REPAIR UNDER THE RECALL OR WARRANTY UNTIL A MANUFACTURER INVESTIGATOR INSPECTS THE VEHICLE IN A MONTH. THE REAR DIFFERENTIAL WAS REPLACED. THE DRIVER SIDE WINDSHIELD WIPER ARM WAS REPLACED. UPDATED 07/25/06. *JB
A.B.S. LIGHT COMES ON INTERMIT., WHEN TAKEN TO LOCAL DEALER, THEY JUST GO UNDER THE DASH AND "RESET" THE A.B.S. "SENSOR" AFTER SIX MONTHS, THE LIGHT COMES ON AND OFF AT DIFFERENT TIMES. THEY WANT ME TO SPEND $700 . DO I HAVE ANY RECOURSE? *NM
I HAVE A 2002 CHEVY TAHOE AND BECAUSE I LIVE IN CA, I AM NOT COVERED UNDER THE HUB BEARING RECALL. I HEAR NOISES WHEN I BREAK AND SOMETIMES MY CAR JERKS FORWARD WHEN I'M STOPPING. I HAVE HAD NO ACCIDENTS YET BUT I'M UPSET THAT I HAVE TO PAY FOR A PROBLEM THAT IS AN APPARENT ISSUE. *JB
DT: THE CONTACT STATED ABS BRAKE SYSTEM MALFUNCTIONED. THE DEALER AND MANUFACTURER INFORMED THE CONTACT THAT HIS STATE OF RESIDENCE WAS NOT INCLUDED IN NHTSA RECALL 05V379000 CONCERNING ANTI LOCK BRAKES. *AK THE CONSUMER STATED WHEN HE APPLIED THE BRAKES, THE ABS WOULD ENGAGE WHICH MADE IT DIFFICULT TO STOP THE VEHICLE. U…
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DT: THE CONTACT STATED ABS BRAKE SYSTEM MALFUNCTIONED. THE DEALER AND MANUFACTURER INFORMED THE CONTACT THAT HIS STATE OF RESIDENCE WAS NOT INCLUDED IN NHTSA RECALL 05V379000 CONCERNING ANTI LOCK BRAKES. *AK THE CONSUMER STATED WHEN HE APPLIED THE BRAKES, THE ABS WOULD ENGAGE WHICH MADE IT DIFFICULT TO STOP THE VEHICLE. UPDATED 11/29/05. *JB
THE CONSUMER'S 2002 CHEVROLET TAHOE HAS ANTI LOCK BRAKE ISSUES. WHEN TRYING TO APPLY THE BRAKES VEHICLE DID NOT COME TO A COMPLETE STOP. SAW RECALL 05068 T ON NHTSA'S WEBSITE. THE DEALER WILL NOT COMMIT TO DO A RECALL REMEDY. AND GM DID FEEL IT HAS TO DO A RECALL. THE CAR WAS UNSAFE TO DRIVE. MY WIFE DROVE INTO A INTERSECTIO…
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THE CONSUMER'S 2002 CHEVROLET TAHOE HAS ANTI LOCK BRAKE ISSUES. WHEN TRYING TO APPLY THE BRAKES VEHICLE DID NOT COME TO A COMPLETE STOP. SAW RECALL 05068 T ON NHTSA'S WEBSITE. THE DEALER WILL NOT COMMIT TO DO A RECALL REMEDY. AND GM DID FEEL IT HAS TO DO A RECALL. THE CAR WAS UNSAFE TO DRIVE. MY WIFE DROVE INTO A INTERSECTION AND FORTUNATELY NOBODY GOT HURT.*AK THE SENSORS WOULD PULSATE AND CAUSE THE VEHICLE NOT TO STOP. *NM
Official recalls
305V379000 · Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip
Aug 29, 2005
CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES MAY EXPERIENCE UNWANTED ANTILOCK BRAKE SYSTEM (ABS) ACTIVATION. THIS CONDITION IS MORE LIKELY TO OCCUR IN ENVIRONMENTALLY CORROSIVE AREAS. THIS RECALL WILL BE LAUNCHED IN THE "SALT BELT" STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MARYLAND, MASSACHUSETTS, MAINE, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN AND THE DISTRICT OF COLUMBIA ONLY.
Consequence & remedy
Consequence: THIS CAN CAUSE INCREASED STOPPING DISTANCES DURING LOW-SPEED BRAKE APPLICATIONS, WHICH COULD RESULT IN A CRASH.
Remedy: DEALERS ARE TO REMOVE THE WHEEL SPEED SENSOR AND THOROUGHLY CLEAN THE WHEEL SPEED SENSOR MOUNTING SURFACE ON THE BEARING, APPLY RUST INHIBITOR TO THE CLEANED SURFACE, GREASE THE MOUNTING SURFACE, REINSTALL THE WHEEL SPEED SENSOR, AND CHECK THE PEAK-TO-PEAK OUTPUT VOLTAGE TO ENSURE THE WHEEL SPEED SIGNAL IS WITHIN SPECIFICATIONS. THE RECALL BEGAN SEPTEMBER 22, 2005. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438 OR GMC AT 1-866-996-9463.
03V094000 · Structure
Mar 7, 2003
CERTAIN PICKUP TRUCK, VAN, AND MINI VAN CONVERSIONS EQUIPPED WITH SOUTHERN COMFORT BUILT RUNNING BOARDS THAT CONTAIN CERTAIN COURTESY LIGHTS MANUFACTURED BY AMERICAN TECHNOLOGY COMPONENTS, INC. THESE UNITS CONTAIN A COURTESY LIGHT OR LIGHTS THAT MIGHT OVERHEAT WHEN THE WIRE HARNESS IS EXPOSED TO EXCESSIVE MOISTURE AND ROAD SALT.
Consequence & remedy
Consequence: THIS OVERHEATING CONDITION CAN CAUSE THE RUNNING BOARD TO MELT OR CAUSE A FIRE.
Remedy: DEALERS WILL REPLACE THE WIRING HARNESS ON THESE RUNNING BOARDS. OWNER NOTIFICATION BEGAN MARCH 7, 2003. 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 SOUTHERN COMFORT AT 1-800-745-6096.
02V253000 · Seats:front Assembly:head Restraint
Sep 17, 2002
ON CERTAIN SPORT UTILITY VEHICLES EQUIPPED WITH REARWARD FOLDING HEAD RESTRAINTS ON THE SECOND ROW SEATS, TWO POTENTIAL PINCH POINTS EXIST ON EACH OF THE FOLDING HEAD RESTRAINTS WHEN THE RESTRAINTS ARE FOLDED REARWARD AS THE SEATBACK IS FOLDED DOWN.
Consequence & remedy
Consequence: IF A PERSON WERE TO INSERT THEIR FINGER(S) INTO THE PINCH POINT WHEN THE HEAD RESTRAINT FOLDS, IT COULD TRAP AND PINCH THE FINGER(S) CAUSING INJURY.
Remedy: DEALERS WILL INSTALL PROTECTIVE COVERS OVER THE PINCH POINTS. OWNER NOTIFICATION BEGAN NOVEMBER 8, 2002. 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, GMC AT 1-800-462-8782, OR CADILLAC AT 1-800-458-8006.
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
5EA11001 · 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
DP05009 · Parking Brake Failure
Opened Dec 20, 2005 · Closed May 31, 2006
Status: closed (inferred from source dates) · Parking Brake; Parking Brake:conventional; Parking Brake:conventional:mechanical
ODI'S REVIEW OF COMPLAINT DATA RECEIVED SINCE THE CLOSE OF EA04-011 REVEALED NO INDICATION THAT THE INVESTIGATION SHOULD BE RE-OPENED.MORE DETAILS CAN BE FOUND IN THE FEDERAL REGISTER NOTICE ENCLOSED IN THE DP05-009 PUBLIC FILE.ODI RESERVES THE RIGHT TO REOPEN THE INVESTIGATION IN THE FUTURE SHOULD CONDITIONS WARRANT.
Additional source detail variants (3)
Parking Brake:conventional
ODI'S REVIEW OF COMPLAINT DATA RECEIVED SINCE THE CLOSE OF EA04-011 REVEALED NO INDICATION THAT THE INVESTIGATION SHOULD BE RE-OPENED.MORE DETAILS CAN BE FOUND IN THE FEDERAL REGISTER NOTICE ENCLOSED IN THE DP05-009 PUBLIC FILE.ODI RESERVES THE RIGHT TO REOPEN THE INVESTIGATION IN THE FUTURE SHOULD CONDITIONS WARRANT.
Parking Brake:conventional:mechanical
ODI'S REVIEW OF COMPLAINT DATA RECEIVED SINCE THE CLOSE OF EA04-011 REVEALED NO INDICATION THAT THE INVESTIGATION SHOULD BE RE-OPENED.MORE DETAILS CAN BE FOUND IN THE FEDERAL REGISTER NOTICE ENCLOSED IN THE DP05-009 PUBLIC FILE.ODI RESERVES THE RIGHT TO REOPEN THE INVESTIGATION IN THE FUTURE SHOULD CONDITIONS WARRANT.
Parking Brake
ODI'S REVIEW OF COMPLAINT DATA RECEIVED SINCE THE CLOSE OF EA04-011 REVEALED NO INDICATION THAT THE INVESTIGATION SHOULD BE RE-OPENED.MORE DETAILS CAN BE FOUND IN THE FEDERAL REGISTER NOTICE ENCLOSED IN THE DP05-009 PUBLIC FILE.ODI RESERVES THE RIGHT TO REOPEN THE INVESTIGATION IN THE FUTURE SHOULD CONDITIONS WARRANT.
PE05020 · Unwanted LOW-SPEED Abs Activation
Opened Apr 28, 2005 · Closed Sep 13, 2005
Status: closed (inferred from source dates) · Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip; Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module
IN A LETTER DATED AUGUST 29, 2005, GM NOTIFIED ODI THAT IT WAS RECALLING CERTAIN MODEL YEAR 1999 THROUGH 2002 C/K PICKUP TRUCKS AND SPORT UTILITY VEHICLES TO CORRECT A PROBLEM WITH ANTI-LOCK BRAKE SYSTEM (ABS) WHEEL SPEED SENSOR CORROSION THAT MAY RESULT IN UNWANTED ABS ACTIVATION AND EXTENDED STOPPING DISTANCES DURING LOW-SPEED BRAKING (RECALL 05V-379).GM'S RECALL COVERS APPROXIMATELY 804,000 VEHICLES CURRENTLY REGISTERED IN THE FOLLOWING 14 SALT-BELT STATES:CONNECTICUT, ILLINOIS, INDIANA, MASSACHUSETTS, MAINE, MICHIGAN, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, AND WEST VIRGINIA.THE RECALL PROCEDURE WILL INVOLVE REMOVING THE SENSOR, CLEANING THE MOUNTING SURFACE, APPLYING A RUST INHIBITOR (ZINC-X) TO THE SURFACE, AND REINSTALLING THE SENSOR.IF NECESSARY, THE SENSOR WILL BE REPLACED. THE POPULATION AND FAILURE REPORT DATA GIVEN IN THIS RESUME ARE FOR THE FULL REGION THAT HAS BEEN CONSIDERED BY ODI AS THE SALT-BELT.THAT INCLUDES DELAWARE, IOWA, MARYLAND, MINNESOTA, MISSOURI, WISCONSIN AND THE DISTRICT OF COLUMBIA IN ADDITION TO THE 14 STATES INCLUDED IN 05V-379.THE STATES COVERED BY GM'S RECALL HAVE THE HIGHEST INCIDENT RATES FOR THE SUBJECT CONDITION, ACCOUNTING FOR 91% OF THE INCIDENTS, BUT ONLY 24% OF SUBJECT VEHICLE SALES IN THE UNITED STATES.ODI'S ANALYSIS DETERMINED THAT 840 OF THE COMPLAINTS, 244 OF THE CRASHES, AND 16 OF THE INJURIES IDENTIFIED IN THIS INVESTIGATION OCCURRED IN THOSE STATES.THE RESULTING INCIDENT AND CRASH RATES ARE 96.2 AND 28.0 PER 100,000 VEHICLES RESPECTIVELY (NOTE:RATES ARE BASED ON VEHICLE SALES, NOT REGISTERED VEHICLES). THE CORRESPONDING NUMBERS IN THE EXCLUDED PORTIONS OF THE SALT-BELT ARE 399,000 VEHICLES, 81 INCIDENTS (20.3 PER 100,000 VEHICLES), 3 CRASHES, AND NO INJURIES.THE STATISTICS IN THE REMAINING 30 STATES ARE 2,406,000 VEHICLES, 168 INCIDENTS (7.0 PER 100,000 VEHICLES), 31 CRASHES, AND ONE INJURY.GM AND ODI ARE CONTINUING TO MONITOR THE PROBLEM EXPERIENCE IN STATES THAT ARE NOT INCLUDED IN THE RECALL.GM WILL PROVIDE ODI WITH UPDATED COMPLAINT, FIELD REPORT, AND WARRANTY DATA IN NOVEMBER 2005.ODI AND GM WILL REVIEW THAT DATA AND ASSESS THE APPROPRIATENESS OF THE CURRENT SCOPE OF THE RECALL AT THAT TIME.
Additional source detail variants (2)
Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module
IN A LETTER DATED AUGUST 29, 2005, GM NOTIFIED ODI THAT IT WAS RECALLING CERTAIN MODEL YEAR 1999 THROUGH 2002 C/K PICKUP TRUCKS AND SPORT UTILITY VEHICLES TO CORRECT A PROBLEM WITH ANTI-LOCK BRAKE SYSTEM (ABS) WHEEL SPEED SENSOR CORROSION THAT MAY RESULT IN UNWANTED ABS ACTIVATION AND EXTENDED STOPPING DISTANCES DURING LOW-SPEED BRAKING (RECALL 05V-379).GM'S RECALL COVERS APPROXIMATELY 804,000 VEHICLES CURRENTLY REGISTERED IN THE FOLLOWING 14 SALT-BELT STATES:CONNECTICUT, ILLINOIS, INDIANA, MASSACHUSETTS, MAINE, MICHIGAN, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, AND WEST VIRGINIA.THE RECALL PROCEDURE WILL INVOLVE REMOVING THE SENSOR, CLEANING THE MOUNTING SURFACE, APPLYING A RUST INHIBITOR (ZINC-X) TO THE SURFACE, AND REINSTALLING THE SENSOR.IF NECESSARY, THE SENSOR WILL BE REPLACED. THE POPULATION AND FAILURE REPORT DATA GIVEN IN THIS RESUME ARE FOR THE FULL REGION THAT HAS BEEN CONSIDERED BY ODI AS THE SALT-BELT.THAT INCLUDES DELAWARE, IOWA, MARYLAND, MINNESOTA, MISSOURI, WISCONSIN AND THE DISTRICT OF COLUMBIA IN ADDITION TO THE 14 STATES INCLUDED IN 05V-379.THE STATES COVERED BY GM'S RECALL HAVE THE HIGHEST INCIDENT RATES FOR THE SUBJECT CONDITION, ACCOUNTING FOR 91% OF THE INCIDENTS, BUT ONLY 24% OF SUBJECT VEHICLE SALES IN THE UNITED STATES.ODI'S ANALYSIS DETERMINED THAT 840 OF THE COMPLAINTS, 244 OF THE CRASHES, AND 16 OF THE INJURIES IDENTIFIED IN THIS INVESTIGATION OCCURRED IN THOSE STATES.THE RESULTING INCIDENT AND CRASH RATES ARE 96.2 AND 28.0 PER 100,000 VEHICLES RESPECTIVELY (NOTE:RATES ARE BASED ON VEHICLE SALES, NOT REGISTERED VEHICLES). THE CORRESPONDING NUMBERS IN THE EXCLUDED PORTIONS OF THE SALT-BELT ARE 399,000 VEHICLES, 81 INCIDENTS (20.3 PER 100,000 VEHICLES), 3 CRASHES, AND NO INJURIES.THE STATISTICS IN THE REMAINING 30 STATES ARE 2,406,000 VEHICLES, 168 INCIDENTS (7.0 PER 100,000 VEHICLES), 31 CRASHES, AND ONE INJURY.GM AND ODI ARE CONTINUING TO MONITOR THE PROBLEM EXPERIENCE IN STATES THAT ARE NOT INCLUDED IN THE RECALL.GM WILL PROVIDE ODI WITH UPDATED COMPLAINT, FIELD REPORT, AND WARRANTY DATA IN NOVEMBER 2005.ODI AND GM WILL REVIEW THAT DATA AND ASSESS THE APPROPRIATENESS OF THE CURRENT SCOPE OF THE RECALL AT THAT TIME.
Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip
IN A LETTER DATED AUGUST 29, 2005, GM NOTIFIED ODI THAT IT WAS RECALLING CERTAIN MODEL YEAR 1999 THROUGH 2002 C/K PICKUP TRUCKS AND SPORT UTILITY VEHICLES TO CORRECT A PROBLEM WITH ANTI-LOCK BRAKE SYSTEM (ABS) WHEEL SPEED SENSOR CORROSION THAT MAY RESULT IN UNWANTED ABS ACTIVATION AND EXTENDED STOPPING DISTANCES DURING LOW-SPEED BRAKING (RECALL 05V-379).GM'S RECALL COVERS APPROXIMATELY 804,000 VEHICLES CURRENTLY REGISTERED IN THE FOLLOWING 14 SALT-BELT STATES:CONNECTICUT, ILLINOIS, INDIANA, MASSACHUSETTS, MAINE, MICHIGAN, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, AND WEST VIRGINIA.THE RECALL PROCEDURE WILL INVOLVE REMOVING THE SENSOR, CLEANING THE MOUNTING SURFACE, APPLYING A RUST INHIBITOR (ZINC-X) TO THE SURFACE, AND REINSTALLING THE SENSOR.IF NECESSARY, THE SENSOR WILL BE REPLACED. THE POPULATION AND FAILURE REPORT DATA GIVEN IN THIS RESUME ARE FOR THE FULL REGION THAT HAS BEEN CONSIDERED BY ODI AS THE SALT-BELT.THAT INCLUDES DELAWARE, IOWA, MARYLAND, MINNESOTA, MISSOURI, WISCONSIN AND THE DISTRICT OF COLUMBIA IN ADDITION TO THE 14 STATES INCLUDED IN 05V-379.THE STATES COVERED BY GM'S RECALL HAVE THE HIGHEST INCIDENT RATES FOR THE SUBJECT CONDITION, ACCOUNTING FOR 91% OF THE INCIDENTS, BUT ONLY 24% OF SUBJECT VEHICLE SALES IN THE UNITED STATES.ODI'S ANALYSIS DETERMINED THAT 840 OF THE COMPLAINTS, 244 OF THE CRASHES, AND 16 OF THE INJURIES IDENTIFIED IN THIS INVESTIGATION OCCURRED IN THOSE STATES.THE RESULTING INCIDENT AND CRASH RATES ARE 96.2 AND 28.0 PER 100,000 VEHICLES RESPECTIVELY (NOTE:RATES ARE BASED ON VEHICLE SALES, NOT REGISTERED VEHICLES). THE CORRESPONDING NUMBERS IN THE EXCLUDED PORTIONS OF THE SALT-BELT ARE 399,000 VEHICLES, 81 INCIDENTS (20.3 PER 100,000 VEHICLES), 3 CRASHES, AND NO INJURIES.THE STATISTICS IN THE REMAINING 30 STATES ARE 2,406,000 VEHICLES, 168 INCIDENTS (7.0 PER 100,000 VEHICLES), 31 CRASHES, AND ONE INJURY.GM AND ODI ARE CONTINUING TO MONITOR THE PROBLEM EXPERIENCE IN STATES THAT ARE NOT INCLUDED IN THE RECALL.GM WILL PROVIDE ODI WITH UPDATED COMPLAINT, FIELD REPORT, AND WARRANTY DATA IN NOVEMBER 2005.ODI AND GM WILL REVIEW THAT DATA AND ASSESS THE APPROPRIATENESS OF THE CURRENT SCOPE OF THE RECALL AT THAT TIME.
PE03026 · Steel Wheel Rim Fracture
Opened Jun 12, 2003 · Closed Nov 3, 2003
Status: closed (inferred from source dates) · Wheels; Wheels:multi Piece; Wheels:rim
THERE HAVE BEEN LESS THAN 2 COMPLAINTS PER 100,000 SUBJECT VEHICLES RELATED TO THE ALLEGED DEFECT.THE OLDEST VEHICLES (MY 1999) HAVE ONLY 2 COMPLAINTS IN OVER 140 THOUSAND VEHICLES AFTER OVER 4 YEARS IN SERVICE.THE RATE OF WARRANTY CLAIMS POTENTIALLY RELATED TO THE ALLEGED DEFECT IS LESS THAN 0.1%.THERE ARE NO KNOWN INCIDENTS INVOLVING RAPID LOSS OF TIRE PRESSURE OR LOSS OF VEHICLE CONTROL. A DEFECT TREND 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 NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.
Additional source detail variants (3)
Wheels
THERE HAVE BEEN LESS THAN 2 COMPLAINTS PER 100,000 SUBJECT VEHICLES RELATED TO THE ALLEGED DEFECT.THE OLDEST VEHICLES (MY 1999) HAVE ONLY 2 COMPLAINTS IN OVER 140 THOUSAND VEHICLES AFTER OVER 4 YEARS IN SERVICE.THE RATE OF WARRANTY CLAIMS POTENTIALLY RELATED TO THE ALLEGED DEFECT IS LESS THAN 0.1%.THERE ARE NO KNOWN INCIDENTS INVOLVING RAPID LOSS OF TIRE PRESSURE OR LOSS OF VEHICLE CONTROL. A DEFECT TREND 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 NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.
Wheels:multi Piece
THERE HAVE BEEN LESS THAN 2 COMPLAINTS PER 100,000 SUBJECT VEHICLES RELATED TO THE ALLEGED DEFECT.THE OLDEST VEHICLES (MY 1999) HAVE ONLY 2 COMPLAINTS IN OVER 140 THOUSAND VEHICLES AFTER OVER 4 YEARS IN SERVICE.THE RATE OF WARRANTY CLAIMS POTENTIALLY RELATED TO THE ALLEGED DEFECT IS LESS THAN 0.1%.THERE ARE NO KNOWN INCIDENTS INVOLVING RAPID LOSS OF TIRE PRESSURE OR LOSS OF VEHICLE CONTROL. A DEFECT TREND 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 NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.
Wheels:rim
THERE HAVE BEEN LESS THAN 2 COMPLAINTS PER 100,000 SUBJECT VEHICLES RELATED TO THE ALLEGED DEFECT.THE OLDEST VEHICLES (MY 1999) HAVE ONLY 2 COMPLAINTS IN OVER 140 THOUSAND VEHICLES AFTER OVER 4 YEARS IN SERVICE.THE RATE OF WARRANTY CLAIMS POTENTIALLY RELATED TO THE ALLEGED DEFECT IS LESS THAN 0.1%.THERE ARE NO KNOWN INCIDENTS INVOLVING RAPID LOSS OF TIRE PRESSURE OR LOSS OF VEHICLE CONTROL. A DEFECT TREND 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 NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.
EA02015 · Throttle Sticking Closed
Opened Aug 1, 2002 · Closed Jan 12, 2004
Status: closed (inferred from source dates) · Vehicle Speed Control:linkages
THIS INVESTIGATION INVOLVES THE GENERAL MOTORS CORPORATION (GM)THROTTLE BODY (TB) UTILIZED IN MODEL YEAR (MY) 1999-2002 SILVERADO, SIERRA, TAHOE, SUBURBAN, AVALANCHE AND YUKON (SUBJECT VEHICLE(S)) WITH 4.8L, 5.3L, AND 6.0L ENGINES. THE TB VALVE MAY INTERMITTENTLY STICK IN A CLOSED POSITION.IN SUCH A SITUATION, AN OPERATOR MAY APPLY ADDITIONAL ACCELERATOR PEDAL FORCE TO INCREASE ENGINE SPEED.THE APPLICATION OF ADDITIONAL ACCELERATOR PEDAL FORCE, TO OPEN A STUCK THROTTLE VALVE, MAY OPEN THE THROTTLE VALVE MORE THAN INTENDED AND, IN TURN, ACCELERATE THE ENGINE AND VEHICLE MORE THAN INTENDED AND REASONABLY EXPECTED BY THE DRIVER.ON AUGUST 1, 2002, THE OFFICE OF DEFECTS INVESTIGATION (ODI), OF THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION (NHTSA), OPENED THIS ENGINEERING ANALYSIS.THE INVESTIGATION REVEALED THAT TWO FACTORS MAY CAUSE THE DEFECT: 1) TB MANUFACTURING PROCESS PROBLEMS; AND 2) ACCUMULATION OF DEPOSITS (A PCV SYSTEM BY-PRODUCT) ON OR AROUND THE TB THROTTLE VALVE AND BORE.ODI CONCLUDES THAT THE TB PERFORMS IN A DEFECTIVE MANNER AFTER ANALYZING GM?S DATA SUBMISSIONS, AND TEST DATA COLLECTED BY THE VEHICLE RESEARCH AND TEST CENTER (VRTC).FIFTY-NINE CRASHES ARE ALLEGED TO HAVE OCCURRED AS A RESULT OF GM?S TB DEFECT.THE MAJORITY OF THE CRASHES INVOLVE A SINGLE VEHICLE, ENGAGING IN A CLOSE QUARTER VEHICLE MANEUVER (OR LOW SPEED), AND CAUSING ONLY MINOR PROPERTY DAMAGE.FOUR OUT OF THE FIFTY-NINE CRASHES INVOLVE INJURY, AND THOSE INJURIES WERE MINOR.ALTHOUGH GM?S TB IS DEFECTIVE, BASED ON THE EVIDENCE GATHERED, ODI HAS FOUND THAT THE ACCELERATOR PEDAL FORCE REQUIRED TO OPEN A STUCK THROTTLE VALVE IS NEGLIGIBLE, AND THE THROTTLE VALVE DOES NOT STICK IN THE OPEN POSITION.THEREFORE THIS ENGINEERING ANALYSIS (EA02-015) WILL BE CLOSED AT THIS TIME.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.FOR A DETAILED DISCUSSION OF THE TB COMPONENT AND TESTING, PLEASE SEE THE ATTACHED REPORT.