Problems with 2002 Chevrolet Silverado 2500HD SERVICE BRAKES, HYDRAULIC

On my 2002 silverado, the abs activates at low speeds causing brakes to pulse and increase stopping distance. clearly nhtsa reference #05v379000 states that this only affects certain states. my vehicle falls into the manufacturer's recall date range as it was manufactured in august 2001. chevrolet refuses to fix this issue under a recall and are telling me that they do not issue recalls that are state specific and that my vehicle does not qualify. needing help getting this issue resolved. *tr

2002 chevrolet silverado 2500. attorney representing consumer writes in regards to engineering analysis of faulty brake lines that failed. *smd

Tl* the contact owns a 2002 chevrolet silverado 2500hd. the contact stated while driving the brakes failed. the contact was only able to stop the vehicle as the speed decreased. the contact took the vehicle to his local mechanic, who stated the brake fluid leaked out and the front and rear brake lines were completely covered with rust. the vehicle was repaired. the failure and current mileage was 132,400. updated 11/01/12 *bf the brake lines were replaced with stainless steel lines. updated 11/02/12

We have just had 27 feet of front brake line replaced for the second time in our 2002 chevy silverado 2500 series. two years ago lost brakes and luckily avoided an accident. gm dealership replaced, and the line failed yet again last week. this time my 19-year-old son was driving with a passenger. luckily, he avoided the cars in front of him at a stop light by crossing two lanes so that he could slow the vehicle down on the grassy roadside. refused to take to gm for repair this time. something has to be done about faulty chevy brakelines in early 2000 chevy trucks before someone loses their life. *tr

Complete brake failure when i applied the brakes to stop. all brake lines coming out of the block by the driverside front door are rusted beyond recognition. rear break line failure occurred in 2010 same brake line condition. i keep my truck clean and do not off road with it. *tr

Tl* the contact owns a 2002 chevrolet silverado 2500 hd. while approaching a stop sign the contact depressed the brake pedal but the brakes would not respond and the pedal went all the way to the floor. the contact was able to stop the vehicle by applying excessive force. the contact inspected the vehicle and noticed that the brake lines were corroded, fractured and leaking. the vehicle was taken to an auto repair shop for diagnostic testing and repairs. the failure mileage was 100,000. updated 12/16/11 *bf

Rusted brake lines. *tr

The brake lines on my 2002 chevy 2500 hd completely blew out causing me to go through a red light ending up in the middle of the intersection. *tr

Brake line failure near abs module inside frame rail under drivers door; failed in owners driveway; used emergency brake to stop; inspection of brake lines indicates severe rusting of all lines in that area. *tr

While coming to a red light, i lost the ability to stop. upon inspection i observed severely corroded and rusty brake lines and fluid leaking from one of the brake lines. *tr

I was driving south on md-235 in lexington park, md when the light at the intersection of md-235 & fdr blvd. turned yellow. i had little room to stop and applied the brakes forcefully, slowing to approximately 25 mph when the pedal went to the floor and i ran through the intersection as the light turned red. no cars were in front of me; an accident did not occur. i used the emergency brake to stop and opened the hood, thinking i had a brake master cylinder failure. i noted fluid dripping from underneath the chassis by the driver's door, & on further inspection, found a rupture in a corroded brake line. i drove home using the emergency brake (rural area; approximately 12 miles), lightly pressing the brake pedal when stopping with the emergency brake to turn the brake lights on. once home, i found virtually every steel brake line throughout the vehicle badly corroded. an internet search provided information that this is a prevailing problem with 1999-2004 chevrolet trucks of all models. a problem this prevalent with this high of a safety concern needs a manufacturer's recall issued for these vehicles. i am the second owner of this vehicle. *tr

Tl* the contact owns a 2002 chevrolet silverado 2500 hd. the contact stated that while driving approximately 4 mph, the brake pedal extended to floor upon engaging. there was a significant delay in the brake response. the failure recurred whenever the vehicle was in motion at low speeds. the vehicle was not diagnosed or repaired. the manufacturer was not notified of the constant malfunction. the approximate failure mileage was 129,016. the vin was unavailable.

Tl* the contact owns a 2006 chevrolet silverado 2500. the contact stated that all the brake lines were rusted and corroded. while driving 15 mph and depressing the brakes, they went all the way to the floorboard. a mechanic inspected the brakes who advised that the brake lines would need replacing. the brake lines were not repaired. the manufacturer was not notified of the failure. the failure mileage was 915,000. updated 10/26/11 *bf updated 10/28/11

Complete loss of front brake system while driving. i noted a soft pedal while sitting at a traffic light and on the next brake apply there was little or no deceleration until the pedal was near the floor. the rear wheels locked up momentarily while slowing the vehicle at the extent of pedal travel. after stopping the vehicle, i noted a steady stream of brake fluid coming from the line when the brake was applied. the brake line running to the abs unit under the driver side door had a large leak in an area of heavy corrosion. upon further inspection i found that most of the brake lines had heavy corrosion on the vehicle although no other leaks were noted. *kb

While pulling out of parking lot of inspection station on to side street, on slight hill, i depressed my brake pedal and it went all the way to the floor. the truck slowly stopped even though i was only doing approximatly 5 mph. when i got out and looked under the truck i saw brake fluid coming from under the driver side of the truck. the inspector had told me that the lines looked to be corroded and i would need to get them replaced in a few years. once the brake failure occured he came and looked again and was shocked that it was an instant braking. *tr

All brake hydraulic lines are rusted, all fuel supply lines are rusted, excessive rust on frame and other undercarriage components, brake rotors, calipers all covered with excessive. rust. these defects have serious safety implications, which could result in injury or death to the vehicle occupants or others. gm should be required to issue a recall on these vehicles and replace all major corroded brake components with non corrosive metals, brake fluid lines, fuel lines, rusted frames and any other components. many accidents will be occurring because of braking failures and frame failure. this recall should be issued immediately before any other failures occur. these gm trucks also have defective steering boxes that feel loose when rounding corners. i have had a 1995, 2001, 2002 chevy and gmc with same problem they never stood behind this problem other than to put some grease in which was a temporary fix. *tr

Upon applying the brakes, the brake pedal "dropped" to the floor and all braking was lost. driver was able to downshift and use the emergency brake to stop safely. upon investigation of the failure, the steel brake lines located below the drivers seat, under the cab, were found to be heavily corroded and ruptured due to the corrosion causing a complete loss of braking power. *tr

Was driving on road when driver pulled in front of me, i had to a quickly applied brakes to slow down. when pushed down the brake pedal just went soft and mushed down. no braking ability was possible. had to swerve into on coming traffic to avoid major collision. other cars swerved out of my way. ~300 yard down the road the truck finally came to rolling stop using lower gear auto transmission to slow truck down. after stopping saw brake fluid pour out of front engine compartment. upon return home saw no sign of leaks in driveway. also there was not visible loss of brake fluids level nor softening of brake pedal prior to this sudden and complete loss bakes. fluids are checked atleast monthly. so brake line or lines ruptured suddenly without warning. the potential for disaster is huge. the hydraulic brake lines appear to have to thinned out from excessive corrosion and then burst (not leak) when heavy brake pressure is applied which is the worst time for brakes to fail. this is personal use vehicle not used for commercial work. however it is driven and used in the snow belt in the winter. if you own one of these trucks and live in the snow belt completely inspect replace your lines before someone dies. failure point was in front area under hood near left wheel right on bracket where 4 lines bend. these are large vehicles and the failure gave no obvious warning signs prior to failure. *tr

2002 chevrolet silverado. stopping from slow speed at intersection anti-lock brakes engaged, truck shuddered, would not stop, hit vehicle directly in front of. have experienced brake issues with vehicle since date of purchase. was taken in for recall, but dangerous brake problems persist. vehicle is unsafe to drive. *tr

Main brake line for rear axle failed. causing diminished braking ability and partial loss of vehicle control entering corner. causing my truck to enter on coming traffic lane until control was regained. examination revealed rear brake line failed along frame rail above gas tank. brake lines appear to be very corroded. i have been told i must replace all the brake lines as they are all corroded. *tr

Excessive brake line rust and failure with loss of service brakes on gm light trucks. i recently had an experience where the metal brake lines broke unexpectedly on my 2002 chevrolet silverado 2500hd light truck. the brake pedal went to the floor while attempting to stop at a neighborhood stop sign. the vehicle had to be stopped from approximately 10mph using the parking brake and downshifting. no accident occurred. a local service station found that most all of the vehicle's brake lines were excessively rusted. all brake lines were replaced at a cost of $650. *tr

I have a 2002 chevy silverado 2500hd nearly caught fire yesterday. a leak developed in the power brake booster/hydro-boost system and power steering fluid was leaking onto my hot exhaust manifold. smoke was pouring from under my hood. i suspect a small fire because of the amount of smoke. by the time i pulled off the road and opened the hood all i saw was smoke from something leaking on the manifold. i got online and found this recall information for 2004-2005 chevy trucks but not 2002. i wanted to inform you that there may be a need to recall 2002 silverado trucks as well. researching dieselplace.com and dieselpage.com this problem is common and widespread. ---------------------------------------------------------------------------------- march 2005 dear chevrolet customer: this notice is sent to you in accordance with the requirements of the national traffic and motor vehicle safety act. reason for this recall: general motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004 model year chevrolet kodiak and certain 2004 and 2005 model year chevrolet avalanche, express, silverado, and suburban vehicles. on some of these vehicles, the hydraulic brake booster's pressure accumulator may crack and/or separate from the hydro-boost assembly during normal vehicle operating conditions. if a separation were to occur and the hood of the vehicle were open, fragments from the accumulator could cause injury to people in the immediate area. in addition, the presence of this crack or fractured surface could allow the hydraulic fluid to leak from the accumulator circuit of the booster assembly. the loss of fluid would cause increased steering and braking effort. what will be done: your chevrolet dealer will inspect the hydraulic brake booster, and replace it if necessary. this service will be performed for you at no charge. *tr

Complete brake line failure as a result of loss of brake fluid due to extensive brake line corrosion. brakes failed during normal driving conditions on i-78 in northern nj. symptoms included brake pedal going "to the floor", as well as greatly reduced braking effectiveness. this is the second failure of this type on this vehicle. the first occurred on 1/24/2007, and is covered under nhtsa report odi #10180807. this new failure was repaired by the dealer, konner chevrolet, in west caldwell, nj. *tr

Brake lines rupture and brakes fail. i've had this happen three times and in researching this problem have seen on-line that it's quite common with my brand of truck. *tr

Hydraulic brake line going to rear of truck failed due to heavy exterior corrosion. truck is a 3/4 ton crew cab with an eight foot bed. the point of failure was near where line crosses to top of frame near a loomed wire harness approximately under rear door of cab. all brake lines on the truck are heavily corroded. *tr

Tl*the contact owns a 2002 chevrolet silverado 2500hd. the contact stated that while driving approximately 70 mph, the rear brakeline separated from the vehicle. the contact was able to bring the vehicle to a stop by switching gears and putting on the emergency brake. the vehicle was towed away due to the severity of the damage. the vehicle was inspected by the and found that there was corrosion on the rear brakeline which caused it to fracture. the vehicle had not been repaired. the failure and current mileages were approximately 152,000. the vin was unavailable.

I was driving my 2002 silverado 2500hd when the vehicle in front of me spun on snow and ended up 90degrees across the road in front of me . i braked but the pedal went to the floor and i had to drive up onto the shoulder and missed crashing into the car by a foot or two . i brought the silverado immediately to the dealer . they told me my brakeline had rusted out and now want $2500 to repair . they say the other lines are also bad and need replacement . the vehicle is now at the dealers while they order parts . *ln

Driving down highway, applied brakes to feel the pedal go to floor. able to stop and inspect after some distance. rear steel brake line under truck bed had corroded through, and with a push of the pedal, brake fluid sprayed everywhere. had to have line replaced from diverter box under cab to rear crossover at driver rear wheel, badly corroded! now it is march of 2012 (107,000 miles), and the front lines from the master cylinder to diverter are leaking as well. thankfully i noticed before driving. i am having the bad line replaced, and i am looking for a stainless steel replacement for all lines! *tr

2002 chevy 2500hd 72k miles original owner... rusted brake lines. pedal went to floor and couldn't stop. thank goodness i was in the driveway of my house. at the dealer right now to be repaired. please see internet to see how many thousands of people that this has happened to .. urgent ..why is this not a recall someone is going to seriously get hurt.. we leave on a country road with a lot of turns and bends... again thank god i was in the driveway.. help!!!!!!!!!! *tr

Tl*the contact owns a 2002 chevrolet silverado 2500 hd. while driving approximately 10 mph, the contact applied the brakes but the vehicle did not stop and was involved in a crash. a police report was filed but no injuries were reported. the vehicle was towed to an authorized dealer where the contact was told the brake lines failed due to severe corrosion. the brake lines were replaced. the failure mileage was 86,000 and the current mileage was 86,500. updated 02/14/11 *bf updated 03/14/11 updated 03/29/11 *bf updated 03/30/11

Tl*the contact owns a 2002 chevrolet silverado 2500 hd. upon entering the vehicle he stepped on the brake pedal and the pedal depressed to the floor. the vehicle was taken to an authorized dealer where he was informed that the brake lines were corroded. the vehicle was in the process of being repaired. the failure and current mileages were 70,000.

2002 chevy silverado ,brake hydraulic lines failed coming to a stop,found line failure due to excessive rust corrosion to brake lines above left frame rail . as i am a auto technician for chrysler and not have seen such rust on brake lines unless vehicle has 200,000 miles or so.this vehicle only has 36,000 miles .i feel that the material the lines are made out of are inferior raw materials. i have replaced the lines that were leaking and plan to replace the rest at some time making them my self with something that may hold up better to my seat belt location.with that said if general motors decides to wake up and recalls the brake lines i would appreciate some restitution,i noticed like me many people have experienced the same issues and had there vehicles repaired and were reimbursed for their troubles. *tr

Without warning my 2002 chevy 2500hd lost it's brakes almost causing an accident. i found that the brake lines had rusted under the left wheel well. i called chevy and they stated that it was not a known issue. they refused to help or discuss the issue with me. i asked to speak to a supervisor and the told me that there was no one else i could speak to. after doing some research online i found that it has been widely reported. *tr

Brake line following frame along driver's side ruptured causing hissing and loss of brake fluid around the rear wheel well. brake line corroded. pedal went to the floor with no braking to stop the vehicle. slowed with loss of momentum and pumping the brake pedal. *tr

I own a 2002 chevy silverado 2500 hd 4x4. in the past couple of months my abs has been activating at low speeds for no reason (conditions dry with no water and ice). it causes me to slow earlier than normal to prevent stopping too late. i have been researching this and it appears that it may be covered by a recall (pe05020). i live in maryland and am not yet sure if my state is covered. i bought my vehicle second hand from a chevy dealer 6/29/04 and have not received a recall notice (i have received others in the past). filing this and contacting my dealer in case nhtsa thinks md should not be covered. the failure occurs daily and causes longer stopping distance. *tr

I am the original owner of a 2002 chevy 2500hd pickup with 65,000 miles. i experienced a total failure of the brake system on 28 aug 2010 due to a ruptured brake line. the leaking line was in the vicinity of the driver's door and all lines were heavily corroded. leak was large enough to fully drain the brake fluid reservoir. failure happened while parking truck at home. no accident occurred, but i was lucky. this failure could have caused a fatal accident. repair of this defect will require replacement of all brake lines on the truck. in my opinion, the root cause of this brake failure is a poor choice of materials (plain steel) for the brake lines. chevy should have used a corrosion resistant material. *tr

Complete corrosion of brake line and failure of brakes. *tr

Tl* the contact owns a 2002 chevrolet silverado 2500 hd. while the contact was driving approximately 25 mph, the brake pedal fell much farther into the floorboard than usual and the vehicle would not decrease in speed. the brake pedal was applied numerous times before coming to a stop. the contact was able to resume with caution. the vehicle was inspected upon arrival at the residence to find the brake fluid leaking onto the ground. the vehicle was towed to an authorized dealer. the contact stated the vehicle was taken an independent mechanic prior to the failure for an unrelated repair where the technician detected the brake line exhibited severe rust corrosion and stated the vehicle was unsafe to drive. also previously, the vehicle was taken to the dealer for a second opinion and they informed that there was not a problem with the brake line. the contact was waiting on a response from the dealer regarding the recent failure at the time of the complaint. the failure mileage was approximately 24,500.

100% brake failure on 2002 chevrolet 2500 hd. pedal went completely to the floor while driving unexpectedly. i managed to pull off the main highway onto a side road and stopped with the emergency brake. dealer indicated brake lines were rusted through and is in process of replacing. vehicle was purchased new with only 63000 miles. *tr

Tl* the contact owns a 2002 chevrolet silverado 2500 hd. while driving approximately 25 mph, the brake pedal was applied which extended to the floor without any response. the vehicle failed to slow down and in order to stop the trailer brakes were engaged. the vehicle was taken to an independent mechanic where the abs module's main brake line was replaced. the failure recurred and the vehicle was taken to an independent mechanic for the second time; however the main brake line connected to the master cylinder was replaced. the manufacturer was notified of the defect. the approximate failure mileage was 71,662.

While driving my 2002 chevy silverado 2500hd truck and attempting to stop, the brake pedal went to the floor. inspection revealed the brake line from the master cylinder to the proportioning valve under the cab of the truck had burst due to a very rusty brake line. inspection revealed that all the brake lines are very rusty and need to be replaced. *tr

Tl* the contact owns a 2002 chevrolet silverado 2500. while braking from the speeds of 8 mph, the anti lock brakes engaged and caused an unusual increase in stopping distance and time. the contact located a recall for the failure however, the dealer advised the recall was limited to specific states only. the contacts vin was not included in the recall. a diagnostic was performed which determined the failure to be caused by the right abs sensor. the vehicle was not repaired. the failure mileage was 80,000 and the current mileage was 84,000.

Brake line failure due to corrosion while driving my 2002 chevrolet silverado hd2500 pickup. brake pedal went to the floor and could not stop, could only stop by using the emergency brake. scary. the line failed that follows the frame just in front of the drivers door. *tr

During braking my 2002 chevrolet silverado 2500 hd's abs is activated when the vehicle is almost stopped. it happens intermittently but seems to be getting worse. the failure has not yet been repaired. i confirmed with chevy that there is no open recall on this vehicle but there should be. *tr

Fax from detective rusty brake lines on his 2002 chevrolet silverado pickup truck, inquiring why there is not a recall for this issue. *kb the consumer stated when he attempted to apply the brake, it went completely to the floor. the consumer found a hole had completely rusted through one of the brake lines. *jb

I am the original owner of a 2002 chevrolet silverado 2500hd pickup truck. on 12/11/09 while driving the truck, i applied the brakes and the pedal went completely to the floor, leaving me with no brakes. fortunately, i was going very slow at the time and was able to roll to a slow stop with no damage or injury. i found that my brake lines were rusty with a hole entirely through one place. i did an internet search on 'silverado" and 'rusty brake lines' and found numerous other irate owners with the same problem. i contacted general motors and was told i would need to have a dealer inspect the truck before any additional action could be taken. this is the result: i was charged $175.09 for hauling the vehicle 20 miles to the nearest dealer and 'inspecting it; yes, the lines were rusted out as i had told them; general motors will provide no further action because the problem may be the result of 'low mileage'; and the dealer wants to replace the brake lines for $1000.00. i live in north carolina and have driven and worked on vehicles for over 50 years and i have never before had a hole rusted in a brake line. the sudden and unexpected loss of brakes has to be a deadly disaster waiting to happen. *tr

The brake lines on the vehicle rusted out causing brake failure while operating. i had to have all the brake lines replaced. you can see their is a problem with a simple search on the internet. http://trucks.about.com/b/2010/11/09/brake-line-corrosion-suspected-in-gm-trucks.htm. *tr

My 2002 chevrolet silverado 2500 hd was having a problem with the abs system activating at slow speeds when the wheels were not actually sliding. although the wheels were acting exactly as described in recall bulletin 05068c, i was told by the dealer that my truck was not covered even if the problem was due to front wheel speed sensor corrosion as described in the recall. i also called the gm customer assistance center at 800-630-2438 where they also said my truck is not covered even though the vin is within the brackets in the recall. i was given a case number of 71-774131746. i took my truck to larson chevrolet in superior, wi on november 10, 2009 where they inspected my front wheels and found the corrosion described in the recall. i had them repair the corrosion at my expense. i then contacted customer assistance again and they agreed to forward my case to a district specialist. after a couple conversations with the district specialist isaac i was told that my truck would not be covered because 3/4 ton trucks were excluded. no reason for excluding 3/4 ton trucks was given. it seems to me that gm was in error when 3/4 ton trucks were excluded because my truck had the exact problem described in the recall. i would like to see the recall expanded to include 3/4 ton trucks and to have my expenses of $206.47 reimbursed. *tr

Abs slow stop activation, a common complaint with chevrolet trucks and suv,s, chevrolet has refused to fix the problem although it is well documented and some models recalled for the same defect. *tr

2002 chevrolet suburban 2500. in parking lot, pressed brake and truck lurched forward causing damage to my suburban and another car resulting in an insurande surdharge for accident over $2500. dealer, mirak chevrolet of arlington ma could not find defect. upon braking today,i felt a surge forward but no accident this time. please advise of any past recalls or similar incidents. *tr