Problems with 2002 Chevrolet Silverado 1500 SERVICE BRAKES, HYDRAULIC

Sudden metal hydraulic brake line rupture one of two brake line runs between the master cylinder and abs frame mounted controller ruptured. the exterior appearance of the line is extremely rusty. the line is in a bundle of four lines - two going to the abs controller and two returning from the abs controller to each of the two front wheels. the other three lines have extremely rusty surfaces and appear near rupture as well. the failure occurred when braking for a traffic light and was made apparent by the brake pedal suddenly dropping to the floor. no accident or injuries occurred. the failure is not yet corrected. i have only called repair shop for estimate. the estimate was $400 to $600 per line or $1600 to $2400 for replacing all four lines based on material cost plus $82 / hr labor. *tr

Tl*the contact owns a 2002 chevrolet silverado 1500. the contact stated that when approaching a stop sign or traffic light, the abs engages too early and the brake pedal vibrates. the vehicle was taken to a service station and it was discovered that the calipers needed to be replaced due to rust build up. the vin was unknown. the current mileage was 105,000 and failure mileage was 10,400.

I have a 2002 chevy silverado that was part of a recall for anti-lock brakes engaging at low speeds (4-10mph). i took my truck to a dealership to have the recall service performed in 2006. now, in 2008, as i was driving through town, my anti-lock brakes kicked in and i almost wrecked into the car in front of me. it now happens on a regular basis everytime i try to brake at low speeds. i called chevy technical support and they were of no help whatsoever. they could not offer a good explanation as to why they would not fix my problem, even though they acknowledge it is a problem and a safety hazard. *tr

Tl*the contact owns a 2002 chevrolet silverado 1500. while driving 7 mph, the anti-lock brakes activated without warning. the contact stated that he had release the brakes then depressed them again to stop the vehicle. there was a recall repair made for the service brakes, hydraulic: antilock (nhtsa campaign id # 05v379000) in january of 2006. the contact felt that remedy for the recall was not sufficient. as of may 16, 2008, the dealer had not inspected or repaired the vehicle. the current and failure mileages were 100,000.

Tl*the contact owns a 2002 chevrolet silverado 1500. the contact received a safety recall notice for nhtsa campaign id number 05v379000 (service brakes, hydraulic: antilock) in march of 2008. he took the vehicle to the dealer to be repaired, but the part was unavailable. at that time, the brakes were cleaned and inspected and the contact was informed that the part would be in soon. as of april 18, 2007, the part is still unavailable. when the contact depressed the brake pedal while driving at an unknown speed, the antilock brakes activated. the vehicle is currently parked. the purchase date was unknown. the current and failure mileages were 119,000.

Tl*the contact owns a 2002 chevrolet silverado 1500. while driving 55 mph, the abs warning light remained illuminated. the dealer replaced the abs at the cost of $1,046.36. the failure mileage was 64,000 and current mileage was 64,500. updated 04-02-08 *bf

I have a 2002 chevrolet silverado truck. the truck only has 28,000 miles on it and recently began making grinding noises. i took it to century chevrolet and was told that all 4 rotors and pads need to be replaced. with only 38,000 miles on the truck that seemed crazy. when i questioned this they told me that they hardly ever see this brake problem happening and it's because i don't drive the truck enough so it's rusted out the parts. rusty parts in colorado is another thing that didn't make sense. they could only do the front brake repair because of my camper so they replaced the front rotors and pads for a little over $400. i started checking around about the brakes and discovered on the internet that there were many similar stories from other silverado owners. there is a large number of people who own these vehicles with parts that just deteriorate. chevrolet continues to deny that it's defective parts and instead tells people that it's their fault for not using the brakes enough. we use this truck mostly in the summer for camping and traveling but do drive it in the winter so i?m unsure what is considered the proper amount of ?braking? time. the dealer couldn?t give me an answer on that question. this is happening to a lot of other people and they should be warned that part of the maintenance on this vehicle is $1,000 brake job every $25,000 miles or you won't have any brakes. thank you for your time. *tr

Rusted brake lines possible brake failure. *tr

Pulling into a parking spot at a slow rate of speed, the antilock brakes kicked in and i could not stop. i ended-up hitting the car in front of me causing 1,100 in damage to her car. this issue was supposed to be fixed in a recall in oct 2005. the fix was a bandaid to the real problem. the abs system is in these trucks are faulty. i was told the best thing to do is take the fuse out of the truck for the abs. *tr

Abs system failure...brakes fail to work at slow speeds. previous recall work on this system performed by dealer, still not fixed. *tr

Tl*the contact owns a 2002 chevrolet c1500. while driving 5 mph and approximately 3 feet away from another vehicle, the brakes were applied, but the vehicle continued to move forward. the contact stated that the brakes made a very loud noise before the vehicle stopped. the vehicle has not been inspected by a repair shop. the brakes and both sensors were replaced approximately two years ago. the engine size was unknown and the vin was invalid. the current and failure mileages were 35,600. updated 11/6/07 *tr

Tl*the contact owns a 2002 chevrolet silverado 1500. while applying the brakes between 5 and 10 mph, the abs pulsates and the vehicle will not stop. the failure caused the vehicle to crash into a fence. the bumper was dented. the contact stated that the brakes pulsate 8 out of 10 times and increase the vehicle's stopping distance. he has had one abs sensor unplugged in order to deactivate the abs. nhtsa campaign id number 05v379000 (service brakes:hydraulic:antilock) was referenced. the current and failure mileages were 73,500. updated 01/11/08. *lj updated *jb

Tl*the contact owns a 2002 chevrolet silverado 1500. while driving 10 mph, the vehicle became difficult to stop when the abs attempted to engage. the dealer stated that the failure was caused by the speed sensor and the abs hub. the current and failure mileages were 59,000.

Tl*the contact owns a 2002 chevrolet silverado 1500. while driving 30 mph the vehicle lost the ability to stop when he attempted to make a turn. the road conditions were normal. the vehicle was towed to the dealer and they stated that the brake lines rusted which caused brake fluid to leak. the dealer replaced two brake lines and the contact was advised to repair the other brake lines that started to rust. the current and failure mileages were 90,000.

The brakes on my 2002 silverado are terrible. at low speeds the brake pedal goes to the floor and the truck will not stop. my wife refuses to drive the truck. i use it to pull my 2 horse trailer and the trailer brakes stop the vehicle. the chevy recall on these brakes should be extended to all states! i live in florida and obviously my truck has been affected by the faulty abs sensor issue. *nm

Dt*: the contact stated while applying brake pressure at 10 mph in a parking lot, there was an increased stopping distance, and the vehicle struck a lighting pole. there were no injuries but there was vehicle damage sustained. the police were not alerted. also, the dealer and manufacturer were not alerted as well. updated 12/28/2006 - the consumer contacted the manufacturer. the manufacturer informed the consumer that a recall had been issued. the recalled antilock brakes were replaced by the manufacturer. *nm

Dt*: the contact stated while braking from various speeds, the anti-lock brake system did not engage and the brake pedal went almost all the way to the floor of the vehicle. this caused an extended stopping distance and nearly caused a crash. there was a nhtsa recall #05v379000 which pertains to the hydraulic anti-lock service brakes. the vehicle was not included in the recall due to the vin. the pcv valve and fuel filter were replaced. the rear brake pads were replaced and the rotors were machined, the rotors were eventually replaced, there was noise coming from the front end. the intermediate steering shaft was dry. updated 01/09/07. *jb

When driving on interstate brakes will begin to apply without action by the driver, causing vibration and over heating of rotors and stiff brake pedal, this happens after about 15 miles on the interstate and brakes have not been applied. *jb

While attempting to park vehicle, the abs system activated for apparent reason, causing the car to hit a wall. took vehicle to dealer, they duplicated problem, told me that there was a recall for that problem. gm contacted and initially confirmed problem, now after two weeks they are denying any problem exist ... *nm

Dt*: the contact stated while traveling 10 mph in normal driving conditions, brake pressure was applied and there was an increased stopping distance. the vehicle was exposed to excessive road salts. the vehicle was taken to the dealer to await inspection. there was a nhtsa recall, # 05v379000, regarding service brakes, hydraulic:antilock. the vehicle was not included in the recall due to the vin. the manufacturer was notified.

Tl* - the contact stated that on 08/25/06 he took his 2002 chevrolet silverado for recall campaign# 05v379000 service repair, on the abs. after picking up his vehicle he continued to have the same failure. the contact stated that it takes longer for him to come to a complete stop than expected. the contact stated that he has informed the dealership about this problem and has gotten no resolution. the contact stated that this happens almost every day he drives the vehicle regardless of the weather or road conditions.

2002 silverado pu, braking distance is extended. spongy brakes. once when moving into parking space brakes failed to stop car at 5 mph. no damage. when carrying moderate loads brakes never seem reliable. checked by local mechanic, says ok, but issue remains. *tr

My submission pertains to campaign id number 05v37900. i would like to inform your office that the same problem occurs on guam as well as the other states you have mentioned in t the recall report. it occurs in both my vehicles 1999 gmc yukon 2002 chevrolet silverado both of which i believe have recalls pertaining to the anti-lock brake system. *jb

Dt*: the contact stated while driving 67 mph over a bridge with brake pressure applied, the brakes failed and the vehicle struck the bridge. no injuries were sustained. the police were on the scene and a report was taken. the vehicle was inspected by an independent inspector who was unable to duplicate the problem. updated 10/4/2006 - the inspector did find four codes stored for the brakes. gm explained that this failure was not the result of the open recall 05v379000 which had not yet been performed on the vehicle. the vehicle sustained damaged to the left side of the cab and box. *nm

Dt*: the contact stated when the vehicle was taken to a private repair shop for maintenance, the mechanic observed that the metal on the rear rotor shields was rusted through. there was a nhtsa recall # 05v379000, pertaining to corrosion of the antilock service brakes. the vehicle was not included in the recall due to the vin.

Tl*the contact owns a 2002 chevrolet silverado 1500. when the contact depressed the brake pedal, he heard a grinding noise. he had the tires rotated and asked the mechanic if he could examine the brakes. he noticed a chunky rust build-up on the back surface of the brakes. the dealer stated that the rear brake pads were most likely wearing at an angle. the contact was informed that he would probably need new rotors and brake pads installed. the manufacturer has not been notified. the current mileage was approximately 43,000 and failure mileage was approximately 34,000.

Abs system failure abs light on 77,000 miles 2002 silverado gm will not admit it has a manufacturing defect with the abs system - after searching the internet i find there are an abundant of abs failures. *jb

in regards to nhtsa campaign id number: 05v379000, i live in the western mountains of virginia and i am having the identical problems associated with the above mentioned recall. i don't think gm realize that there is a part of virginia, like west virginia, that gets a lot of chloride on the roads in the winter months. the vehicle has had a couple of near accidents due to the malfunction of the abs system. i have removed the fuse to the system until i have the problem fixed. *jb

Dt*: the contact stated, while pulling into a parking space at 3 mph, there was an unwarranted abs activation hindering the brakes from stopping the vehicle. the vehicle's brakes were inspected and cleaned by dealer's mechanic. this incident relates to gm's recall # 05068 (wheel speed sensor). the failure occurred 15 separate times since the inspection.*ak updated 7/18/2006 - *nm

I own a 2002 chevrolet silverado 2wd. when applying the brakes and coming to a stop, there is a pulsation. it feels as if the abs is taking over and releasing, and then reapplying the braking action, rapidly, as i come to a stop. i spoke to a gm representative about a recall that has been issued regarding this problem. the gm recall number is 05068. the representative told me that my vin number was included in the recall, but because i don't live in a "salt belt" state, my vehicle is not being recalled (i live in florida). apparently, it is the road salt that is used during the winter months that corrodes the abs wheel sensors and leads to this problem. and, although i do not live in a state that uses road salt, i do use my vehicle to tow and launch a boat in the salt water. i believe that because of this use, my vehicle should be included in the recall. *jb

I drive a 2002 chevrolet silverado z71. in november 2004 the abs brake system would activate every time i would press the brake at speeds less than 10 mph. i took it to the gm service and they had to replace the entire hub assembly because the sensors were corroded. a recall was issued on the sensor problem. recently i have an abs light that comes on everytime i start moving. occasionally the brake light also comes on. i took it in to gm service and was told that the abs pump assy and module were both broken and repair costs would be about $2000. i was told that the brakes worked fine, i just wouldn't have the abs feature. however i believe the abs system is an important safety feature on a vehicle, especially in areas that experience inclement weather. in addition, the service representative told me that the abs light is triggering the occasional brake light. the false positive is dangerous because it can cause complacency where drivers would ignore a real brake failure. i understand that it's impossible for automobile components to last indefinitely. however, it's obvious that general motors trucks have efficient brake systems, especially concerning the abs. *jb

Tl* the contact owns a 2002 chevrolet silverado 1500. the contact stated that when braking from 5mph, the abs braking system would activate erroneously. the vehicle was taken to the dealer for repairs under nhtsa campaign id number: 05v379000 (service brakes, hydraulic: antilock) however, the failure persisted. the vehicle was not repaired a second time. the manufacturer was not notified of the failure. the failure mileage was 53,000 and the current mileage was 94,000.

Spongy brakes, no brakes at times. last incident feb. 1, 2006 while backing in drive. pushed on brake and pedal went to floor. a loud rattling, hammering noise came from vehicle and no braking felt. i have complained about this since i bought the truck in 2003 at 22586 miles. the master cylinder was rebuilt about april 23, 2004 and it didn't help; in fact we about lost all braking going home from dealer. i phoned the dealer and he ordered a new master cylinder. it was replaced may 3, 2004 but the pedal was still spongy and braking very poor. when stopped and engine running you can push the brake pedal clear to the floor. i have been told this is normal. well, normal almost caused a wreck on a down hill t road with my wife with me. i phoned chevrolet customer assistance center (file 1-212176923) for help. a waste of time. i phoned chevrolet motor division (1800-222-1020) and all they suggested was to take the truck back to the dealer, a 30 mile drive one way. they didn't help in four other visits . i did take it back on jan. 6, 2006 for a brake recall on wheel detectors but it didn't help the braking a bit. thanks. *nm

On 2002 chevy silverado 1500 w/only 25,500 miles, noticed a noise in rear brakes. when rotating tires, discovered both rotors were rusted and corroded, but with plenty of brake pad and thereby causing abnormal wear on brake pads. took vehicle to local gm dealer for inspection by service personnel, who determined same problem, but would not provide good will repair. for obvious safety reasons, purchased replacement rotors and brake pads and completed repairs on our own. we have contacted gm to try to obtain refund of our costs, but not yet resolved the issue. research indicates that gm is aware of this problem with brake rotors. additionally the vehicle still experiences problem w/abs speed sensor requiring additional braking distance at slow speeds, but was not included in the first recall by gm. previously reported this complaint. *jb

Dt: the contact received a recall letter for the abs sensors he had the work performed, but the abs pump has gone bad. he contacted general motors, and they stated that because maintenance on vehicle was not performed at a gm dealership they would not assist him with the repairs. *ak updated 11/29/2005 - *nm

Tl* the contact owns a 2002 chevrolet silverado 1500. while the contact was driving approximately 5 mph approaching a traffic stop sign, pressure was applied to the brake pedal, suddenly the anti-lock brake system engaged and the vehicle rolled forward. in 2005, the vehicle was repaired under a manufacturer voluntary recall pertaining to the anti-lock brake system. the identical failure recurred in january of 2011 and was repaired by the dealer. most recently, the brakes completely failed to respond upon engaging and the vehicle was towed to the dealer. the contact was waiting upon a response from the dealer in regards to the cause of failure. the manufacturer was made aware of the failure. the approximate failure mileage was 55,000.

Abs brake system has been recalled for 2002 silverodo trucks in several states west va. being one of them i live within 10 min of west, va. we are a state that gets a lot of road salt. my brake sensor system has gone out . the champaign number is 05vb379000. virginia needs to be added to this recall list i have just had one side repaired at a cost of $333.00 now the other side is bad. this recall started in august but will not be issued untill nov. 2005 there could be several accidents and maybe injuries or fatalities before nov.please help to have virginia included in this recall at least the mountians of south west virginia thank you for yor assistance. *nm

Our silverado has the exact problem described in recall #05v37900 for the anti-lock brakes. because we are not considered a "salt belt" state g.m. will not recall our truck.*jb

Tl*the contact owns a 2002 chevrolet silverado 1500. the contact received a recall notice for nhtsa campaign id number (service brakes, hydraulic:antilock). the dealer cleaned the speed sensor, but did not replace any parts. the failure has recurred and the brakes stick when attempting to stop the vehicle at low speeds. on the fourth trip to the dealer, the contact was informed that no failures could be found. she is unsure if the dealer will replace or clean the sensor, but she requested that it be replaced. in addition, the intermediate steering shaft was replaced with a re-manufactured part in july of 2005 at 18,031 miles. in november of 2006, at 29,650 miles, the steering shaft was lubed. in april of 2008, at 43,194 miles, the steering shaft was replaced a second time. currently, at 56,000 miles, the vehicle is still experiencing issues. the dealer must check and replace the shaft failures every 25,000 miles. lastly, the rear brake rotors were resurfaced four times and all of the window regulators have to be replaced. the vehicle is currently at the dealer to have all of the issues repaired. the failure mileage was 18,031. updated 07/02/09. *lj

Dt*: the contact stated the vehicle brake pads had normal wear patterns but on the inside of both rotors the wear pattern should have been approximately 2 inches but were 3/4 inches. also, there was corrosion on the rotor which caused the brake pad to wear inconsistently. the hydraulic disc brakes had extended stopping distance. failure occurred under normal braking situations. the design of braking system was 4-wheel anti-lock and the nature of the failure was worsening. the contact notified the service dealer who determined it was normal to get corrosion on the rotor. also, the manufacturer advised the contact to take the vehicle to the dealer. the vehicle was taken to the independent shop to replace the rotor and the brake pads. *ak updated 09/05/06. *jb

At low speeds the abs system engages when the break is applied causing the truck to brake poorly. until just recently i've had no problems and my brake pads are fine per my mechanic who checked them about 2 weeks ago. while driving the truck i pulled into a friends driveway about 5mph and applied the brake on dry pavement when the abs came on and i was sent crashing into his garage. this has happend almost 20 times since that day. i can not even drive my truck to work anymore due to fear of hitting someone. i have a 2002 silverado xc 1500 4x4 that is very well maintained with 81332miles. my father and brother both own similar model gm trucks both 2000 models with exactly the same problem. nothing has been done as of yet to fix my truck i'm waiting to see if i can make the dealer pay for the damages done and fix my brake system.

Driving 2002 chevy silverado 1500 pickup. slowing down to stop in traffic and/or sudden stops at slow speed causes antilock brake system to activitate and requires farther stopping distance.

Front speed sensors failed in 2005 before the recall on my 2002 chevy silverado z71. had recall taken care of in 2005. they are failing again this year 2011 and now the rear brake line just ruptured yesterday 12/18/2011. my husband agrees that salt at is part of the problem with the brake lines but the abs sensors is an on going chevy problem in these trucks and once the recall is performed once, the future failures are up the owner to fix and cover the cost. my truck is a 2002 but it only has 76,000 miles on it. all these braking issues should not be happening. and seriously they build these right here too, although mine says built in fort wayne , indiana, you would think they would be better made. and why did the stuff start really failing after my extended warranty ran out? go figure. *tr

At 37720 miles on 2002 chevrolet 4x4 pickup. took vehicle to dealer for safety inspection and service to gm dealership. was informed that vehicle would not pass inspection due to brake rotors and pads being rusted and worn out. this was in march 2005. in october 2005 received recall notice relating to severe corrosion between front hub/bearing and speed sensor. filled for a claim reimbursement due to the fact that all parts were inter related. also even the repair invoice stated worn out/rusted. was informed that no reimbursement would be paid.*ak

Complaint ref [xxx] on mar 12,2005 i had a failure of the abs brake system that resulted in a complete brake failure! i stopped the vehicle by turning off the ignition. the failure was in a parking lot at slow speed. i had the same type of failure on aug 3,2004. i reported it to the nhtsa at that time. last aug gm ok'd a warranty fix by using service bullt. # 02-05-006a-(nov 26,2002). at that time there was damage to the front of the vehicle due to running into a fence. after complaining, they agreed to pay for fixing the damage. now back to the present failure. the dealership said the problem this time was the wheel hub assemblies which the abs sensors are attached. contacting gm, i told them i believed the repair should be covered under the warranty even though my mileage was 36,500. they said it would not be covered under warranty because it was 3 months and 500 miles over the warranty. i did not agree with them as i see this as a continuation of last august's problem and that it wasn't fixed correctly at that time. i had the truck fixed and paid the $631 myself. i am contacting you because i believe there is an abs brake problem with the vehicle that is not peculiar to my vehicle but no doubt is widespread. i know you do not have an investigation at this time but i think there should be? the fact that there is a bulletin on it tells me it is happening to other vehicles! my vehicle is a 2002 chevy silverado full size pick up. it is not 4 wheel drive and is a c1500. veh id # is [xxx]. thank you for your help. [xxx]. *jb *js information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6)

Some times when pushing down on the foot brake, it becoming stiff and won't depress. at this time the use of the hand brake has to be used to stop. if had several close calls, but no accident so far.

Vehicle had grinding noise from rear wheels and loss of power. rear brakes failed with 9, 975 miles on vehicle. dealer found right rear brake caliper rusted solid and not operating, causing inner right disk brake pad to wear out prematurely. was advised that this was a result of the vehicle not being used enough, allowing components inside the caliper to rust. dealer rebuilt right rear calipers, turned down both excessively rusted rear rotors and replaced rear disc brake pads.

Chevy truck began a vibration and chattering in brake pedal at low speed . *bf the abs braking system wheel had locked up. *sc

The consumer took the vehicle through inspection and it was determined that the rotors had rusted. the rotors were turned instead of being replaced by the dealer. the consumer was driving the vehicle approximately 3 months later and the vehicle was hard to stop when the brakes were applied. the consumer took the vehicle to the dealer again and it was discovered that the bearing and hub assembly was defective and it was replaced on the left side. *jb

When the consumer applied the brake while driving 3 mph to park the vehicle the abs activated which resulted in extended stoppingdistance. the vehicle hit a barrier wall which caused $85 in damage. *ak *nm