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Problems with 2004 Chevrolet Silverado 2500HD SERVICE BRAKES

On average, the 2004 Chevrolet Silverado 2500HD starts to “feel” problems with the SERVICE BRAKES and its various aspects after 110 784 miles.

Recently reported SERVICE BRAKES problems on 2004 Chevrolet Silverado 2500HD

I have changed all 4 new tires in 4 different times every yrs not sure if that a wheel problem. and also fix my fuel injection system that was give me a problem in the past. now i replace all new rotor brake discs and pad in 30 minutes out from a mechanical shop it's show a engine light now saying range shift inhibited on my dashboard. and when i'm shifting to drive it just reverse instead of drive. now is back in the shop for now problem to come. from garden city kansas

Brake lines failed after having already been replaced. factory lines corroded through and truck was scary to slow down. was fortunate to be going at low speeds in a residential area - but glad there were no kids around and i needed to brake quickly!

Total brake failure when attempting to slow/stop vehicle to make a turn. drove into parking lot to get off of roadway, hit sign, tree, parked vehicle before vehicle finally stopped.

Brake lines and related calipers continue to rust and fail. have now lost brakes while driving due to failure of various brake lines three times. twice i lost the brakes while driving in highway traffic. once while backing slowly down a ramp to a dock. have had lines replaced 3 times now. calipers also replace. vehicle in shop for emergency repair now. previous dealers have said this problem is related to the new brine material applied to roads by dot in winter. note that i do clean undercarriage to remove salt. also have had several older vehicles other makes/ models during same time period and have not had this issue. never replace brake lines on other vehicles. *tr

Engine runs rough at idle.ck engine light on.

While traveling 50 mph towing a boat applied the brakes , the vehicle slowed down and the brake pedal went to the floor with the units finally stopping . all brake failure warning lights light up on the dash and upon inspection it was discovered the brake line to the right front wheel had rusted through and blew out all the brake fluid directly under the drivers door. all remaining brake lines are severely rusted and appear swollen as to be ready to burst as well under the drivers door along the frame rail. vehicle has 2,760 engine running hours on it with 82,500 miles driven. all brake lines are original to the truck .dealer estimate to replace all brake lines was in excess of $2,000. this vehicle is only driven on the highway and never off road. i have owned many vehicles over the years and this vehicle is the only one that has suffered a catastrophic brake failure which thankfully did not end in a crash. after further investigation with other similar truck owners i have discovered this has been a common problem that in now surfacing and may result with tragic consequences if not addressed by nhtsa and gm immediately.

On 4/28/2016 traveling to work following a tractor trailer in a 55 mph zone, the tractor trailer abruptly merged into the right turn lane after a curve without a signal leaving two stopped cars in my travel lane making a left turn. i applied hard pressure to my brakes and the pedal went to the floor. i impacted an avalanche that was pushed into a small compact car causing substantial damage to my vehicle and the avalanche. the driver of the avalanche was transported to the hospital with minor injuries. while at the accident scene i noticed fluid leaking under my truck just behind the left rear tire. the truck was towed from the scene to a body shop where they discovered 2 ruptured brake lines in between the master cylinder and proportioning valve. attached pictures show severally rusted brake lines with no other rust or corrosion on parts in the surrounding area. initial estimate for repairs on my truck were $6,371 before tear down.

Going down exit ramp brake pedal went to floor. had i not managed to get vehicle stopped with aggressively pumping brake pedal while ready on parking brake we would have gone into three lanes of cross traffic got vehicle home and found extremely corroded brake lines underneath driver side with one leaking over the years i've worked around equipment and never seen anything this bad on a passenger vehicle of any kind. we live in the south and this vehicle is not affected by extreme winter conditions. the vehicle has been well maintained and i consider this a serious safety concern.

On my way home from work the rusted brake lines on my truck failed. sadly, gm has known for years that these lines were made poorly and that this has been an issue. yet they have failed to notify consumers or voluntarily replace these parts with some of higher quality. unfortunately, the nhtsa isn't any better, as they have been "investigating" this issue for a number of years but have yet to force the auto maker to correct this problem. clearly not enough people have died from this issue to merit them working in the publics best interest and not be in the auto makers back pocket.

I have had a complete brake job because all of the lines rusted out and failed as i was driving. fortunately, i was able to use the emergency brake to stop safely. i spent rough.y $3,000 to get this repaired. now the fuel lines, fuel cooler and everything attached has rusted out to the point that it is going to be an additiona $2,500 to repair this. also, the complete under carriage and rear end has rusted to the point that i am expecting it to fail at any time. this is not only a dangerous situation, but is extremely costly to the consumer, me. when the brakes failed, i was driving on a street approaching a busy intersection. with no warning at all, the pedal went to the floor and i had no brakes. the repair facility mechanic said he has never seen a system so bad. i keep the vehicle in a garage and have washed the under carriage in the winter to keep road salt from accumulating.

Brake pedal went to the floor trying to avoid hitting another car traveling at 60 mph on the interstate , steel brake line under drivers door rusted and broke .

I was towing my rv. when i hit the brakes and the brake pedal went to the floor. scared the blank out of me since i had my wife and two kids with me. the brake line for the rear brakes blew due to corrosion. the only thing that saved us was the trailer brakes or we would have had a serious accident. gm is so cheap they build their brake system with lines that easily corrode in stead of stainless. there should be a recall. the internet is littered with this issue. there should be a regulation forcing manufacters to use corrosion proof brake lines. ridiculous!!!

Tl* the contact owns a 2004 chevrolet silverado 2500 hd. while driving approximately 10 mph, a humming sound emitted from the accelerator pedal that became louder when the vehicle accelerated. also, the contact stated that the brake pedal was difficult to depress without warning. the failure recurred numerous times. the vehicle was taken to an independent mechanic, where it was diagnosed that the brake hydro booster needed to be replaced or rebuilt. the vehicle was not repaired. the manufacturer was made aware of the failure and stated that the vin was not included in nhtsa campaign number: 05v043000 (service brakes, hydraulic). the approximate failure mileage was 216,000.

Brake line blew and brakes went to the floor. *tr

I was traveling home from dropping my dog off at his groomer. i went to brake coming to an intersection to prepare for a change in the light when the brake pedal went straight down to the floor with no warning light in the gauges or information system until after the incident happened. i had very little braking at all and was able to get the truck to my resident without incident. i had the truck towed to a mechanic who informed me the brake line had rusted completely through. i have read many complaints being filed by other chevy silverado owners. when is gm going to be held responsible for failing parts on all of their vehicles? i was a lucky individual that it was early morning and very lite traffic on the road i was traveling. *tr

Everything appeared normal when i was driving to the bank. as i was slowing to make the turn into the bank the brakes felt a little spongy. as i pulled up to the atm brakes continue to be spongy. finished at bank and cautiously started driving home. first stop light, i had to gear down to slow to allow me to stop as the brake hit the floor. pumping helped me stop in time to not hit the car in front of me. i should have probably called for a tow at that point, but only had back roads left to get home. drove very slow (less than 5mph) by time home had no brakes left. going slow enough to hit curb opposite of my driveway to stop and then backed into uphill driveway so gravity stopped me to put in park. btw - no emergency brake to help, that is not working. got out and a steady stream of brake fluid was coming out from under the drive side door. looked under vehicle and saw fluid leaking from corroded (rusted) brake line between master cylinder & abs box. took a look at all the other line and surprised to see how corroded all of the brake lines are. i was also kind of surprised to see how horrible the entire underside, including frame, have rusted for a 10 year old truck. definitely very upset the brake lines are that corroded and will all need to be replaced to provide confidence another one is not going to burst. i'm just very happy i didn't get in an accident and i sure hope it doesn't take someone dying for gm to issue a recall. given the size of these vehicles and the shear damage they could do to property or human life should be a concern to gm. i'm a huge fan of gm/chevy trucks, but pending what happens may dictate my next truck. my truck has been sitting as i have not had time to try to repair myself or money available to be able to take the chance at how much a shop is going to charge. *tr

I had to apply my brakes because of a sudden stop. when i did my abs brakes worked for a second when no more brakes. had to swerve ,to not hit car in front of me. when i stopped i was two feet past that cars right rear fender. when i looked under my truck there was brake fluid leaking from brake line above frame at drivers door. this could have been alot worse. i heard this is no the only time this has happened with this make and model of vehicle. *tr

Was entering drive-thru restaurant, gave order, proceeded to window to receive order/pay. noticed that upon stopping at window, brake pedal started to depress normally, and then went all the way to floor. within a few seconds smoke started coming into driver compartment thru air vents, smoke could be seen coming out of engine from under hood. quickly proceeded to move vehicle to empty parking spot/area.turned vehicle off, extinguished fire burning in engine compartment. brake line burst sending brake fluid onto exhaust manifolds igniting engine compartment insulation. could have been a serious incident/fatality of my 5 year old daughter and myself and/or others if traveling at speed and/or not able to extinguish fire quickly. this is an engineering defect with a high potential to cause fatalities/injury that needs to be addressed by the manufacturer. *tr

Puddle of brake fluid on driveway. brake line just above gas tank from junction block to rear axle rusted out at clip attachment point with frame. truck was always garage kept and when washed at automatic car wash most times with a under body rinse. *tr

Returning home, i proceeded to back into my driveway, i applied the brakes to reverse into the driveway and the brake pedal went to the floor. very minimal if any brake force was left to stop my truck. i got it back into the driveway, got out and brake fluid was dripping on the ground under the front part of the truck. i determined the fluid was coming from a brake line. i called for a flat bed wrecker, took it to tuffy auto centers at 11524 n saginaw st clio mi. they told me that these brake lines are known to corrode out, and needed to be replaced. i paid to have all brake components inspected and all lines replaced. the cost for parts and labor to me was $531.58. my aaa membership paid for the wrecker. i did not know this was a very common problem known to gm, and that it should have been addressed. i feel this could have been a very bad accident. i had just come home from being on the expressway. *tr

Pulling my boat on secondary road toward highway, pushed brakes to stop for stop sign, brake pedal went to the floor with no warning or trouble light. had enough braking force to stop after rolling approx 100 ft. cautiously drove to gas station/parked vehicle and called a wrecker to take truck 65 miles to my home. on inspection i discovered corroded brake line(steel) had ruptured along routing to back brake. lots of corrosion visible on multiple steel lines. i was incredibly lucky to not be traveling faster and in an emergency braking situation. *tr

I had just returned home with a full load (2 yards) of mulch and parked the truck to unload. the truck was perfectly fine. when i finished unloading i went to move the truck and the brake pedal went to the floor and the driver information center indicated "low coolant level". when i checked out what was wrong, i found two brake lines severely rusted with one leaking located under driver's seat area where the lines cross over top of the frame. that is the only area that rusted that i saw so far. there is no other rust underneath on the rest of the lines. my truck does not get heavy use, is frequently housed in a garage and rarely driven in snow/ice conditions (i'm retired). in addition the truck is well maintained and kept clean. in addition, the low coolant level i believe is a computer glitch as the level is fine and unchanged before and after the incident. in my opinion the truck's computer is sending the wrong message for a defect in the primary braking system. *tr

As i was backing up the truck to hook up our horse trailer i experience a sudden loss of hydraulic pressure in the braking system and the break pedal went to the floor. i was able to stop the truck before it hit the trailer or my daughter who was directing me. i noticed a puddle of fluid on the ground under the truck just below the driver seat and traced it to a crack in a corroded brake line. we were very lucky that the failure occurred when it did. had the brake failure happened 10 minutes later, we would have been traveling on i95 in very crowded conditions with a horse in tow. there had been no indication that the brake system was at risk of failure. we had used the truck the previous weekend to trailer our horse to a show and the brakes worked fine. *tr

Coming out of my driveway, which is approximately 1200 feet long, i hit the brake pedal which went straight to the floor, without even slowing the truck from 15 mph (it is very slightly downhill near the very end). i crossed the road and was hit by an oncoming vehicle approaching my driveway. fortunately, the vehicle was a friend slowing to enter my driveway and the collision was minor. destroyed my rear bumper and damaged the left rear quarter panel. had the oncoming vehicle been traveling at a normal rate of speed for this road, it would have been much worse. likely with injuries. it is a rural road with a 35 mph speed limit and people generally drive it at 40-45 mph. *tr

I was planning on heading up to the mountains to my cabin today (8/10/2014). i stopped for diesel at king's quick stop, about 3 blocks from my house. after i filled up, i put it in drive and the brakes failed completely. by the grace of god i was only going 5 mph in the gas station parking lot or i could have easily hit cars or pedestrians causing injury or loss of life. i drove home using the emergency brake which is not in a great place for emergency stopping. after arriving home i took a look and discovered that the brake lines in one particular section were completely corroded and one of them had burst. this is a vehicle that i frequently drive to the mountains and i cannot fathom how this could happen on any truck, let alone a heavy duty truck. no warning light came out to inform me that my brake pressure was low although i figured that out quickly when my foot went all the way to the floor. after diagnosing the problem, i did some searching on the web and discovered this is a common problem in the salt belt states. but i live in north carolina so this is quite a surprise. i will be scheduling repairs tomorrow but my understanding is that gm is not assisting in any way and that the repairs can run up to $2000. i've owned 20 cars in my lifetime, many with excessive mileage and have never had brakes fail before. so this is quite unsettling and clearly gm has a faulty and dangerous design here. *tr

I was driving and went to stop the brake pedal went to the floor. i put the shifter into low 1 and hit the emergency brake to come to a stop just short of hitting the honda civic in front of me with the baby in the back seat. i put my hazards lights on and checked the truck. under the bed was wet with brake fluid. the brake line was rusted through and is snapped letting all of the fluid out. so, no brakes! *tr

Pulling boat trailer up out of the boat ramp and brake peddle went to the floor and leaked out all the fluid had it towed to garage and found brake line had rusted through on one of the 4 others were in bad shape lucky i wasn't towing the boat down the highway and had to stop i could have killed someone or myself gm needs to address this problem now i hear there has been a lot of complaints. *tr

My wife, daughter, and i were traveling down a two lane highway at the 55 mph speed limit. a oncoming vehicle pulled out to pass another vehicle. when i stepped on the brake pedal to avoid a collision, the pedal went all the way to the floor. thankfully, the oncoming vehicle went back to their lane and we were able to coast to a stop. upon examination, all four brake lines on the front half of the truck were badly rusted and leaking. the undercarriage on our 2004 chevy silverado is extremely rusted. fuel lines. transmission cooler lines, brake lines, frame, body panels all have large amounts of rust. we purchased this vehicle new in 2004. it has never been in a flood. *tr

I was leaving my home to do an errand, while nearing an intersection i applied pressure to the brake pedal when it dropped to the floor . i had to apply serious pressure to get it slowed enough to turn around to head uphill towards home. notice i said slow down, not stop. had i gone seconds further i would have been in far worse shape as there is a steep decline for about 3/4s of a mile just past the intersection where the line gave out. i have had brake lines go bad before in other vehicles but was always able to stop the vehicle within a reasonable distance. i think if i had been on a main road with traffic and a generally faster speed allowance there would have been an accident. something should be done to better supply the use of front brakes when the rear brakes fail and vice versa. *tr

While applying moderate brake pressure in heavy morning traffic on clean dry pavement, the brake pedal collapsed to the floor, followed by rear brake lock-up. i swerved to avoid a collision. i was forced to use the parking brake to move to safety. inspection revealed a metal brake line failure. in fact, all brake lines were severely rusted. i thought this was highly unusual. however one work colleague and one neighbor immediately revealed that they had suffered the same failure on other gm trucks of that age. my mechanic reported doing several dozen brake line replacements on gm trucks in the 2000 to 2006 era. surely this is a major class safety problem. *tr

While stopped in a parking lot the brake pedal went to the floor. closer inspection revealed that the hard brake line had burst above the fuel tank on the line that runs between the abs module and rear axle. *tr

I was traveling on a two-line road nearing the city and near the top of a hill when a line of cars slowed quickly in front of me. i had to get onto the brakes quickly to maintain a safe following distance, but when i did the pedal went completely to the floor. having very little time to react, i noticed the traffic in the oncoming lane had stopped or slowed greatly about 100 yards in front of me, so i was able to swerve into the left lane to avoid rear ending an entire line of cars with my 6000lbs truck. fortunately the driver at the front of the oncoming traffic saw me and stopped. i was then able to barely manage my way back into the right lane as some of those cars started moving again. at this point i was just cresting a large hill at approximately 40mph. a police officer in the oncoming lane had already seen me and activated his lights and then started working to turn around in the road to chase me. when i was back in the right lane i finally had a second to try to locate the parking brake, but activating it had absolutely no effect. i coasted nearly 1/2 mile down the road and forced the truck into a parking lot, over a large set of railroad ties and into a yard with an upsloped hill. if i couldn't have gotten it stopped there i could have coasted down an even steeper hill and into a very busy multi-lane intersection and killed someone. the police officer ended up being understanding of my situation and called a tow truck for me and i had it towed to a shop. the shop said that all of the brake lines were rusted out completely and both the front and rear sets of lines were leaking. i did not have any dash light indicating that the fluid was slow either before or after the incident. the shop owner also told me that these trucks do not have a proportioning valve in order to allow one of the front or rear brakes to continue working in the event of a failure. *tr

Driving home from my wife's parents hose on rt 40, the traffic light changed. and when i depressed the brake pedal, the pedal went to the floor. i started to pump the brake pedal, and was lucky to stop my truck before i went throught the light. i was able to nurse my truck home. the next day i called my mechanic and had the problem taken care of. *js

My wife had just left our house and as she went to stop at a stop sign the brake pedal went to the floor and she had to use the emergency brake to stop. the brake lines had rusted and blew a hole in the lines. *tr

Having new tires and wheels installed at tires direct in waukesha, wi location. pulling out of parking lot and brake pedal went to the floor. line burst midway in frame. using ebrakes went to local garage and they replaced line. $325. *tr

I got in the truck to leave my house. after starting the truck and putting my foot on the brake pedal i shifted into reverse to leave my driveway. at that time the brake pedal went all the way to the floor. i was able to shift back to park as i had not release the parking brake yet. i opened the hood and the master cylinder was empty. after looking under the truck, drivers side inside frame rail, i discovered a burst brake line where it leads into the abs module. all of the brake lines were extremely corroded and had to be replaced with stainless steel at a chevy dealer. i had the dealer perform other routine maintenance items at that time as well. they discovered that i needed to replace a chain guide in my transfer case, and repair a hole that the loose chain had caused. i find it hard to believe that chevy used stainless steel for the exhaust system, which looks great after almost 10 years, yet they used plain steel for the brake lines. i was lucky this occurred in my driveway, and not while i was towing my boat on the highway. the transfer case problem also seems like an engineering failure. *tr

While driving i saw a deer, it started toward the road i was traveling at 50mph the deer started to run to cross my path. i applied my brakes (i should have stopped in plenty of time but....) the pedal went down approximately halfway as normal and held firm, then the pedal continued to the floor, the brakes no longer slowed my truck impacting the deer. a similar incident happened two weeks prior. the first time the left rear brake line failed over the fuel tank. the instant incident the left front brake line failed two inches from the wheel flexible brake line joint. an automobile that is 9 years old should not have brake lines failing, this vehicle has just recently rolled over 100,000 miles mark and is used to pull the family rvs it is not a daily driver. why is steel used for brake lines? it rusts! why is it not coated? why not stainless steel? why put people's lives at risk using cheap materials that rust in a vital safety component such as brakes. *tr

To:[xxx], acting director of the national highway and traffic safety administration please open the link- http://www.wxyz.com/money/auto-news/rusty-brake-lines-cause-concern-for-gmc-chevy-truck-drivers i am writing this email because after the experience i had driving my 2004 chevrolet 2500 silverado 4wd truck to work without brakes due to the fact that general motors installed defective brake lines in their gmc and chevy trucks. (open and read the link above) the last time i had driven my 2004 chevrolet 2500 silverado 4wd truck, my wife and i had just return from a hagerstown, md campground towing our 5th wheel rv trailer, i disconnected the rv from the truck and parked 10 feet in front of the rv. thank god, that the brake failure did not happen while we were driving the 2004 chevrolet 2500 silverado 4wd truck while towing the 5th wheel rv trailer, it may have a caused a very serious accident, and possible serious injury or death. i wonder how many american families suffered with the stress, injuries, or even death due to the indifference from general motors and the national highway and traffic safety administration? information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6). *tr

Had no brakes. discovered ruptured brake line. *tr

Driving to work pushed on the brakes and the pedal went to the floor. inspected to find a rusted brake line broken just under the drivers side front door. also the brake lines have major rust at rear wheel. all of the lines are rusting and need replaced. *tr

Tl* the contact owns a 2004 chevrolet silverado 2500 hd. the contact stated that he started the vehicle and when the brake pedal was applied it was inoperable. the brake fluid was leaking underneath the vehicle. the contact took the vehicle to the dealer who indicated that the brake lines were corroded. the brake lines were replaced along with the master cylinder. the contact indicated that on january 8, 2013 he started the vehicle and the failure recurred. the vehicle was taken to the dealer who indicated that the brakes hydro boost system malfunctioned. the vehicle was not repaired. the manufacturer was notified of the failure and offered no solution. the failure mileage was 122,000.

Brake failure on city street. this is the second time in a year i lost brakes due to brake failure. front brake line was replaced , now back line went. line is very rusty. *js

Arrived home, parked vehicle, noticed fluid dripping from under vehicle near front of driver's door area. inspection showed severely corroded brake lines, and one was dripping brake fluid from corrosion hole. all brake lines inspected and in need of replacement, which was done the next day. *tr

At approx. 6:00 am i left for work which is a 15-20 minute drive. at the first traffic light i noticed the brakes seemed to be low. i continued my travels and at the next light i very nearly was not able to stop. when i reached my business and applied the brakes in the parking lot, they went to the floor and i had to coast to a stop in an empty lot. when i was able to park my truck, i got out of the cab and noticed the vehicle bleeding brake fluid from under the truck. i had to have to brought to my mechanic. upon inspection he found all the brake lines had rusted out and had to be replaced. early this year in january i had to have all the transmission cooler lines replaced in the same truck because they also rusted out completely. between the two repairs it has cost me over $ 1300.00 for a truck with only 30500 miles. this is absolutely ridiculous. if i had been on the highway at a significantly higher speed and my brakes failed in this manner, there would have been a major accident and someone could have been seriously hurt or killed. general motors/chevrolet should be responsible for the repair costs. they have known about the problem and have not notified the owners of their vehicles. *tr

I was driving at normal speed and was traveling down a back road with a car dolly on back when i came up over the hill there were cars stopped and the other lane was coming towards traffic i tried at the top of a very steep hill to apply my brakes and they failed causing me to hit 6 cars and one motorcycle and lucky no one got killed so now i have a damaged truck because of engineers poor design. *tr

Tl* the contact owns a 2004 chevrolet silverado 2500 hd. while the vehicle was being serviced for routine maintenance, the mechanic noticed that the entire front end of the vehicle was defective. the mechanic replaced the steering box, pitman arm, outer tie rod on both ends and the upper ball joint. the contact also stated that the brakes were leaking. the brake leak failure had not been repaired. the manufacturer was not notified. the vin was unavailable. the approximate failure mileage was 200,000.

Backing out of the driveway, foot went to the floor. was able to stop vehicle before impacting traffic. on inspection, large puddle of brake fluid on driveway under driver's door area and all brake lines running to rear of vehicle are significantly corroded and wet from leak above where lines head toward master cylinder. chevy dealer has no recall or investigation information. chevy national service line was no help. would not provide regional service manager contact information. *tr

Every year when it comes to getting an annual inspection on the truck, i always get the same response from the inspection station, failed because of faulty parking brake. i have to pay a mechanic every year to adjust the parking brake just so it can pass inspection. two years ago i got them replaced and paid almost $500 and this year i paid $100 for the shop to adjust them. in the end, brakes were adjust as much as they could and the truck would still roll with the brakes set. they gave me my inspection sticker, but i feel that gm should be required to use bigger brakes. gladly we live in a flat area but to those that live in a hilly area, this could really be a big problem. i ran a cross-reference, autozone.com, and the same parking brake shoes are used for both the diesel engine and the gas engine. the torque on the diesel is much stronger than the gas engine, which i know is the reason that the truck still rolls. *tr

Brake lines rusted through leaking all brake fluid while traveling 65+ on the new jersey turnpike. i am making this report to confirm brake problems on 2004 suburbans as was recently reported in the new york times. cost to repair was in excess of $1000. general motors should seriously consider a recall and possibly consider usually stainless steel tubing for the brake lines! *tr

Corrosion of brake line resulting in total brake failure. *tr

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