Investigations


NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
SERVICE BRAKES, HYDRAULIC
PE04004GENERAL MOTORS CORP.01/08/200404/30/2004HYDRAULIC PUMP SHAFT FAILURES
 The preliminary evaulation is being upgraded.during the ea odi will limitits investigation to only those vehicles equipped with a hydro-boost system, which provides power assist to the braking and steering sytems.vaccuum brake booster vehicles are excluded.odi hasexpanded the scope of the ea to include model years2003 and 2004, asduring the pe, odi learned that the hydroboast pumps were modified in febraury 2004.therefore,odi has expanded the scope to include the additional model years.odi's is concerned because thisisa sudden failure that affects two critical systems of the vehicle, brakes and steering, at the same time.the ability of the operator to handle the dual failures is a concern. further, these vehicles tend to be work vehicles, with some over 10,000 pounds gvwr and many equipped to pull large trailers.dual failures of heavily loaded vehicles and vehicles pulling trailers further increases the safety risk.odi plans to conduct testing to quantify the braking and steering performance degradation and the impact on safe vehicle control, when a hydroboast pump fails.
SERVICE BRAKES, HYDRAULIC - POWER ASSIST
PE04004GENERAL MOTORS CORP.01/08/200404/30/2004HYDRAULIC PUMP SHAFT FAILURES
 The preliminary evaulation is being upgraded.during the ea odi will limitits investigation to only those vehicles equipped with a hydro-boost system, which provides power assist to the braking and steering sytems.vaccuum brake booster vehicles are excluded.odi hasexpanded the scope of the ea to include model years2003 and 2004, asduring the pe, odi learned that the hydroboast pumps were modified in febraury 2004.therefore,odi has expanded the scope to include the additional model years.odi's is concerned because thisisa sudden failure that affects two critical systems of the vehicle, brakes and steering, at the same time.the ability of the operator to handle the dual failures is a concern. further, these vehicles tend to be work vehicles, with some over 10,000 pounds gvwr and many equipped to pull large trailers.dual failures of heavily loaded vehicles and vehicles pulling trailers further increases the safety risk.odi plans to conduct testing to quantify the braking and steering performance degradation and the impact on safe vehicle control, when a hydroboast pump fails.
EA04012GENERAL MOTORS CORP.04/30/200402/28/2005HYDRAULIC PUMP FAILRES05V005000
 Gm is conducting a recall on all subject vehicles build between may 1999 and october 14, 1999.significant changes were incorporated into production in early october 1999, and vehicles built after that date have lower warranty failure rates.the complaint and warranty data appear to support the effectiveness of these changes. gm made additional changes in november 1999, february 2000, may 2001, and february 2004.odi will continue to monitor this problem and will take further action, if warranted, in the future.for further technical details see the attached engineering analysis report.
SERVICE BRAKES, HYDRAULIC - POWER ASSIST - HYDRAULIC
PE04004GENERAL MOTORS CORP.01/08/200404/30/2004HYDRAULIC PUMP SHAFT FAILURES
 The preliminary evaulation is being upgraded.during the ea odi will limitits investigation to only those vehicles equipped with a hydro-boost system, which provides power assist to the braking and steering sytems.vaccuum brake booster vehicles are excluded.odi hasexpanded the scope of the ea to include model years2003 and 2004, asduring the pe, odi learned that the hydroboast pumps were modified in febraury 2004.therefore,odi has expanded the scope to include the additional model years.odi's is concerned because thisisa sudden failure that affects two critical systems of the vehicle, brakes and steering, at the same time.the ability of the operator to handle the dual failures is a concern. further, these vehicles tend to be work vehicles, with some over 10,000 pounds gvwr and many equipped to pull large trailers.dual failures of heavily loaded vehicles and vehicles pulling trailers further increases the safety risk.odi plans to conduct testing to quantify the braking and steering performance degradation and the impact on safe vehicle control, when a hydroboast pump fails.

Consumer Complaints


Fail datemilesoccurencesPurchase date
SERVICE BRAKES
03/01/2013114000
 The brakes failed in an emergency stop situation. a car ran a stop sign in front of me. i applied the brakes hard. the abs kicked in and i avoided a collision. i applied the brakes again and the pedal went to the floor. brake fluid was leaking on the ground from a ruptured brake line. i took to the dealer and they stated that all the brake lines are corroded and require replacement.
01/31/20131415681
 Pulling trailer needed to make a quick stop and the truck would not slow down. if it were not for the trailer brakes i would have rear ended a car trying to make a left turn. stopped at neatest gm dealer and found out one brake line had bursted due to rust and corrosion. ended up have to replace all four brake lines to make my truck safe to drive. cost $800.00. *tr
01/31/2013141568
 Pulling trailer needed to make a quick stop and the truck would not slow down. if it were not for the trailer brakes i would have rear ended a car trying to make a left turn. stopped at neatest gm dealer and found out one brake line had bursted due to rust and corrosion. ended up have to replace all four brake lines to make my truck safe to drive. cost $800.00.
01/03/2003360001
 Brake line failure. abs system failure. light for abs and brake have been on and off since original purchase. dealers could not eliminate the problem. noticed rust on brake lines throughout. currently all brake lines are covered in rust and leaking just prior to the abs components on driver side middle frame rail. brake lines are brittle to the touch. currently the breaking system has no pressure. all fluid has leaked from the system. service requested by dealer for noisy and leaking transfer case. dealer applied grease to the drive shaft. problem not resolved. while driving in 4 wheel drive, the transfer case experienced a catastrophic failure. unit was extremely hot and the gears were ground out. to my knowledge gm is and was aware that the transfer case fluid pumps were wearing a hole in the case from the inside. now know as pump rub. dealers had opportunities to repair and or replace and failed to act to resolve the known damage. *tr
01/03/200336000
 Break line failure. abs system failure. light for abs and brake have been on and off since original purchase. dealers could not eliminate the problem. noticed rust on brake lines throughout. currently all brake lines are covered in rust and leaking just prior to the abs components on driver side middle frame rail. brake lines are brittle to the touch. currently the breaking system has no pressure. all fluid has leaked from the system. service requested by dealer for noisy and leaking transfer case. dealer applied grease to the drive shaft. problem not resolved. while driving in 4 wheel drive, the transfer case experienced a catastrophic failure. unit was extremely hot and the gears were ground out. to my knowledge gm is and was aware that the transfer case fluid pumps were wearing a hole in the case from the inside. now know as pump rub. dealers had opportunities to repair and or replace and failed to act to resolve the known damage.
01/05/2013635601
 One of the brake lines has rusted clear through and ruptured when i pressed on the brake pedal. looking at the other lines, it appears that they are about to rust through as well. i have other vehicles that are much older and more miles that the brake lines are like new. there is a flaw in the lines installed on my truck. *tr
01/05/201363560
 One of the brake lines has rusted clear through and ruptured when i pressed on the brake pedal. looking at the other lines, it appears that they are about to rust through as well. i have other vehicles that are much older and more miles that the brake lines are like new. there is a flaw in the lines installed on my truck.
11/08/20121740001
 Brake lines from engine to abs corroded and burst causing loss of brakes. *tr
11/08/2012174000
 Brake lines from engine to abs corroded and burst causing loss of brakes
10/12/201298016
 All of the steel brake lines on my chevy silverado 2500 hd have severely corroded and are in need of replacement. the truck has not been used off road or in harsh environments and has been regularly maintained. *tr
10/12/201298016
 All of the steel brake lines on my chevy silverado 2500 hd have severly corroded and are in need of replacement. the truck has not been used off road or in harsh enviroments and has been regularly maintained.
08/24/2012627611
 Brake line failure due to corrosion (rust). brake line to rear wheels sprung leak and stopping was difficult. had this been at higher speed, could have fatality. the material the brake lines are made of should not be used to make brake lines. checked brake lines and they are all heavily corroded. all will have to be replaced. similarly the fuel line is heavily corroded between tank and engine. it is apparent that saving a few pennies on cost of brake lines alloy, is more important to gm than the lives of the occupants of the vehicles. *tr
08/24/201262761
 Brake line failure due to corrosion (rust). brake line to rear wheels sprung leak and stopping was difficult. had this been at higher speed, could have fatality. the material the brake lines are made of should not be used to make brake lines. checked brake lines and they are all heavily corroded. all will have to be replaced. similarly the fuel line is heavily corroded between tank and engine. it is apparent that saving a few pennies on cost of brake lines alloy, is more important to gm than the lives of the occupants of the vehicles.
07/29/20121
 Approached stop sign, applied brakes, pedal went to the floor...while towing an enclosed 26' trailer with full load. trailer brakes enabled a controlled stop of vehicles without an accident. brake fluid was dripping from area beneath driver's side door along frame. one (1) line is leaking, with all of the other lines severely rusted (visually). *tr
07/29/2012589221
 I was backing out of my driveway when the brake pedal went to the floor. upon inspection found brake lines rusted and brake fluid leaking. *tr
07/29/20121
 Approached stop sign, applied brakes, pedal went to the floor...while towing an enclosed 26' trailer with full load. trailer brakes enabled a controlled stop of vehicles without an accident. brake fluid was dripping from area beneath driver's side door along frame. one (1) line is leaking, with all of the other lines severely rusted (visually). *tr
07/29/2012589221
 I was backing out of my driveway when the brake pedal went to the floor. upon inspection found brake lines rusted and brake fluid leaking. *tr
07/29/20121
 Approached stop sign, applied brakes, pedal went to the floor...while towing an enclosed 26' trailer with full load. trailer brakes enabled a controlled stop of vehicles without an accident. brake fluid was dripping from area beneath driver's side door along frame. one (1) line is leaking, with all of the other lines severely rusted (visually). *tr
07/29/201258922
 I was backing out of my driveway when the brake pedal went to the floor.upon inspection found brake lines rusted and brake fluid leaking.
07/29/20121
 Approached stop sign, applied brakes, pedal went to the floor...while towing an enclosed 26' trailer with full load. trailer brakes enabled a controlled stop of vehicles without an accident. brake fluid was dripping from area beneath driver's side door along frame. one (1) line is leaking, with all of the other lines severely rusted (visually). *tr
07/29/2012
 Approached stop sign, applied brakes, pedal went to the floor...while towing an enclosed 26' trailer with full load. trailer brakes enabled a controlled stop of vehicles without an accident. brake fluid was dripping from area beneath driver's side door along frame. one (1) line is leaking, with all of the other lines severely rusted (visually).
10/30/2011661001
 Was leaving for a trip and had my trailer on the back. pressed the brake pedal and it went to the floor. looked under the truck to find my brake lines were leaking. *tr
SERVICE BRAKES, AIR - ANTILOCK
07/01/2005507/01/2005
 I just bought a 2001 silverado 2500 truck. the abs warning light came on at low speeds. used car dealership did not know what the problem was. now driving this unsafe heavy truck. worried i might crash and kill someone if the abs fail
SERVICE BRAKES, ELECTRIC
09/14/200861000
 I was driving about 25 mph approaching a red light. i braked to slow down as i approached the rear of the vehicle ahead of me (already stopped). the brakes were functioning properly, then when i slowed to about 5 mph the brake pedal suddenly went to the floor and the brakes stopped working and i hit the vehicle ahead of me at about 5 mph. the air bags did not go off. after the accident my brakes worked and i drove home. my mechanic and my insurance adjuster were both familier with the problem. they said my wheele bearing had corrosion and it caused the abs sensor in the wheele bearing to not work properly and to disable my abs braking system.
SERVICE BRAKES, HYDRAULIC
08/15/200222000
 I purchased a new 2001 chevy hd on august 10,2001. the truck is serviced every 3,000 miles and it has approximately 57,000 miles on the truck. it still looks new both inside and out. at approximately 22,000 miles the back rotors and brakes were replaced then at about 32,000 miles the front rotors and brakes had to be replaced, and then last summer the back brakes had to be replaced and the rotors were turned. also sometime within 30,000 - 45,000 miles all the brake lines had to be replaced as well as two different alternators and a window motor. today (april 20,2012) my wife and i were going to town to get something to eat, when an emergency vechical pulled onto a street that we were on but was going in the oposite direction. i applied the brakes to slow down and pull over and when i did the brakes went to the floor. luckly i had room to move the truck to get out of the way and after some distance we got stopped. we nursed the truck home and its sitting in my driveway again with some type of a brake problem.i think that i have reported this before but a truck that is babied and treated like mine with only 57,000 miles on it that has to have three sets of brakes (not counting the orginal), all the brake lines compleley replaced because they were completely rusted away. rotors replaced front and rear and rotors replaced and turned a second time, and now something brake related broken again should get someones attention. these trucks aren't safe, and no one buys into the environment or lack of driving excuses. i also have a 1997 chevy truck with approximately 126,000 miles with no problems at all, a truck with 57,000 miles that requires two altenators (not counting the orginal), wheel sensors,brake lines / rotors / brakes that you had better not trust and a whole lot of money to keep the thing on the road is not a quality product.
11/19/2011
 I was slowing down, coming to a 4 way stop. that was when the brakes went to the floor board, and i went through the 4 way without stopping!!!! i was very lucky because there was nobody going through that 4 way at that time!!! the brake line under the driver side door had leak do to rusting!!!! also i had just drop off my travel trailer before this happened. couldn't imagine what would have happen trying to stop 9500lbs!!!!!!!!!
09/26/2011108334
 The brake lines on my 2001 chevrolet 2500hd have completely rusted out. i was backing out of my drive way in reverse and went to step on the brake an the pedal went to the floor. i rolled to the end of my driveway, across the street and through my neighbor's fence. my emergency brake only slowed my speed in reverse and did not stop me. the brake line on the driver side rear is rusted through and broken off at the flange at the rear wheel. inspection shows all of the brake lines are severely corroded and will need to be replaced. i am lucky this failure did not happen at a major intersection or in an emergency stop situation on the highway.
07/30/2011138000
 Brake line ruptured while pulling trailer resulting in an accident. brake line that failed was between the master cylinder and the abs box.
10/15/2009125000
 2001 chevy silverado k2500 brake failure. driving home on a country blacktop road, road wet from rain but visibility good. approaching a 45 mph curve i applied the brakes. the pedal was soft and went to the floor quickly. the truck front tires had no brakes and the rears locked up. the truck went into a 360 spin and off the road at approx. 50 mph. the truck went down an embankement and into a swampy area. upon inspection the brake lines to the front wheels had blown out and were extremely corroded. the gm dealer said there was nothing they could do. the truck was totaled. approx. $12,000 loss
05/14/2011127000
 2001 chevrolet silverado 2500hd brake line rupture. steel brake line ruptured @ mount point on frame rail under drivers seat upon backing out of driveway on may 14, 2011. all brake lines are very rusted.
09/29/201050000
 Brakes failed went to floor on 2001 chevrolet hd 2500 4x4. had whole family in vehicle and brakeline burst on rear. all brake lines rotted out
08/10/200120000
 I purchased a new 2001 chevy crew cab 2500 hd truck in august 2001. the truck now (oct 2010) has 50,300 miles on it and has been maintained and serviced reguraly. at approximately 20,000 miles i had to replace both rear rotors and brakes, then at approximately 36,400 miles i had to replace both front rotors, brakes and the alternator. at approximately 40,000 miles the drivers door power window motor had to be replaced and all the brake lines and speed sensors on the truck had to be replaced. now with 50,300 miles, the truck is sitting in my drive way needing another altenator and the rear brakes / rotors are worn out again. since i purchased this truck i have already spent approximately $2800 on brakes, brake lines, wheel / speed sensors and new rotors and replaced the altenator and power door motor. the truck has stranded me two times when the brakes failed and once when the altenator went out. it appears that the dealerships and gm know about these problems but just try to get them past the warrantly period. when i had to replace the front rotors i offered to have the metal / rotors analized to determine why they failed but gm wasn't interested. they paid half on that repair and requested that i leave the rotors with the dealership. i was lucky both times when the brakes failed because we were going slow and on rural roads with minimal traffic, the other time the truck stranded us we we camping on a hoilday weekend and the altenator went out when we were about 10 miles from the camp. these trucks entire brake systems are very dangerous. i think that there needs to be a technical review conducted to evaluate the materials used for the rotors and the brake lines. when my brake lines were replaced they crumbled like flakes of rust and the rotors both front and back were damaged from what apperard to be overheating. there were surface stress flaws on both sides of the rotors. i have owned other gm products, and currently have a 1997 chevy truck with no brake issues
06/26/201072148
 I have just experienced my second brake failure due to corroded/ rusted brake lines in my 2001 chevy 2500hd. both incidents involved normal braking situations approaching intersections. personal inspection of brake lines shows a leak this time above the gas tank the remainder of the lines in the vehicle show significant amount of rust.
06/04/201075000
 Driving when a deer crossed in front of my vehicle. braked hard and brakes went to the floor. found the brake lines under the driver side rusted out. requires replacing all brake lines in the vehicle. severe rust on all lines.
04/10/2010132937
 While pulling in the driveway, i stepped on the brake pedal and had very little braking. i had to apply emergency brake to keep from hitting garage. inspection revealed the front brake line had rusted through and was leaking.
09/21/2009635451
 The brake lines on my 2001 chevy silverado 2500 crew cab have all rusted through brake rushed out and i was left without any brakes. stopped truck with emergency brake and had it towed. what if i had killed someone is that worth the extra 40 dollars for stainless steel lines. come on you are responsible for the publics safety. this problem is widespread. it's a crap shoot every time you drive. *tr
04/10/200521000202/10/2001
 Two failures of hydraulic pump for brakes and steering. pump has been replaced twice at no charge. total loss of steering and braking. *jb
10/07/2005830001
 Loss of steering and braking! cause power steering pump failure. the power steering shaft broke internally. *nm
08/31/200541000109/09/2001
 Vehicle pulls to right when applying brakes at slow speed. *nm
SERVICE BRAKES, HYDRAULIC - ANTILOCK
10/01/20081000001
 I have a 2001 chevrolet silverado 2500hd. the anti-lock brakes on the truck pulse at low speeds as i come to a stop and it seems to take longer to stop in many instances. in investigating this issue on the internet, i found that there was a recall (gm recall 05068, nhtsa campaign id number: 05v379000) that addressed this issue. upon calling chevrolet, i was informed first that there was no such recall. upon challenging that information, i was then told that the recall stopped several thousand units before my vehicle and thus did not apply. *tr
09/15/2006257005011/20/2001
 Anti lock brakes are activating under low stopping speed causing an increase in stopping distance. brought vehicle to ron currier chevrolet in somerworth nh. was told the anti lock brake sensor is out of calibration. tried to resolve the problem with cheverolet as vehicle had only 25,400 miles when incident first occurred. was told of other vehicles covered under a recall, but my vehicle was not included. currently the vehicle has not been repaired. *jb
10/10/2006254003011/12/2001
 Under low braking my anti-lock brakes activated causing my vehicle to have low braking ability and causing the vehicle to take longer to come to a complete stop. *jb
08/10/200520012102/07/2005
 Unwanted anti-lock brake system (abs) during low speed braking applications. which could result in a crash. recall number:05v379000. *jb
10/31/200553500100008/10/2004
 My chev truck 2500hd vin #1gchc23u01f184150 abs system will activate at slow speeds it works fine at higher speeds. i called about the recall 05v37900 and was told this truck was not one of the recalls. it seems to be doing the same thing as the recall states. *nm
04/30/200545500102/28/2004
 Dt: the vehicle is a 2001 chevrolet 2500 hd. when applying the brakes the abs kicks in at low speeds. the contact has been experiencing this problem since the end of april 2005. there have been no accidents as of yet. the contact found a recall for the 1999's with same make and model. when he contacted the manufacturer, they said that it was only vehicles made at a certain plant, that was why this was not included. *ak
08/01/200259000109/01/2001
 When coming to a stop, i loose my braking at about 2 or 3 miles an hour. it doesn't happen all the time. i know that gm is having a recall on my truck in other states, but does not include wisconsin. *jb
03/01/200510200099903/17/2001
 Wheel speed sensor failure - salt contamination - abs engages erroneously - low speed increases stopping distance - my neighbor has the same issue and was just repaired at a dealer at his cost. *jb
05/22/200541000103/01/2001
 Dt: the brakes just do not work properly. abs brakes pulsate, the back tires lock up and the brakes start smoking. *ak
01/07/200437422210/29/2001
 Power steering & power brakes lock up. *la
SERVICE BRAKES, HYDRAULIC - ANTILOCK - WHEEL SPEED SENSOR
05/01/2007104/09/2006
 Safety recall for low speed abs activation 2001 chevy silverado 2500hd. *tr
SERVICE BRAKES, HYDRAULIC - FOUNDATION COMPONENTS - DISC
02/24/200659271103/01/2001
 Dt*: the contact stated there were grinding noises and an increased stopping distance while brake pressure was applied at various speeds. the vehicle was seen by a dealer. the dealer determined the brake discs defoliated and there was metal on metal resulting in poor braking. the dealership replaced the brake pads and rotors which corrected the problem.
SERVICE BRAKES, HYDRAULIC - FOUNDATION COMPONENTS - DISC - PADS
02/24/200659271103/01/2001
 Dt*: the contact stated there were grinding noises and an increased stopping distance while brake pressure was applied at various speeds. the vehicle was seen by a dealer. the dealer determined the brake discs defoliated and there was metal on metal resulting in poor braking. the dealership replaced the brake pads and rotors which corrected the problem.
SERVICE BRAKES, HYDRAULIC - FOUNDATION COMPONENTS - DISC - ROTOR
02/24/200659271103/01/2001
 Dt*: the contact stated there were grinding noises and an increased stopping distance while brake pressure was applied at various speeds. the vehicle was seen by a dealer. the dealer determined the brake discs defoliated and there was metal on metal resulting in poor braking. the dealership replaced the brake pads and rotors which corrected the problem.
05/21/200518100008/11/2001
 While taking my pick up in for its 18000 mile maintenance checkup, the dealership told me that all 4 rotors had to be replaced due to delamination of metal from the surface of the rotor. after inspecting the rotors myself, it was obvious this was the case. prior to this visual inspection, there was no sign of any brake problems. talking to various mechanics, as well as the head of the maintenance department, i could not get a believable answer as to why this occurred. the dealership stated that gm was having this sort of problem, but that it was my responsibility to have the repairs made. several days and $1200 later, i received my truck back with working brakes. however, had this problem not been found at this time, i'm concerned that the brakes could have failed without warning, with obvious consequences.
03/25/200540155108/12/2001
 My brakes started squeaking and i took them to a garage to have them inspected. it turns out that the rear brakes and rotors on my truck had to be replaced due to extreme rust and deterioration. i still have the rotors in my garage. *ak
01/09/2003119001
 Consumer took the vehicle to the dealership to be inspected and the mechanic informed the consumer that all four rotors had disintergrated. *ak the consumer complained previously of brake problems, however he was told there was nothing wrong. *jb
42979112/01/2000
 The front/rear brake rotors rusted and peeled. the dealership indicated this failure was due to the poor quality of the materials used. the parts need to be replaced. *nlm the consumer was told that the quality of the rotors were bad and they should have lasted longer than 42k miles. *scc *jb
SERVICE BRAKES, HYDRAULIC - POWER ASSIST
10/15/200324707103/31/2003
 My power steering pump failed, resulting in significant reduction in braking and steering function. this is of special concern to me as i frequently tow a 10,000 pound fifth-wheel trailer. the failure occurred in october of 2003 and the pump was replaced by the dealer under warranty. *nm
06/21/200475000205/29/2001
 Started cold vehicle. backing out of garage i had no power brakes nor power steering. removed power-steering pump resivoir cap and air and fluid belched out. after that it performed normally.*ak
SERVICE BRAKES, HYDRAULIC - POWER ASSIST - HYDRAULIC
12/30/200354613111/28/2000
 2001 chevrolet 2500hd pickup had a complete power brake and power steering failure almost resulting in a crash as i was almost not able to bring the vehicle to a stop. luckily no one was in front of me. mechanic states that pump shaft had a break in it. i've still got the part if that would help with your investigation. luckily i was not towing my 10,000 pound rv trailer at the time of the failure or i may not have been able to control the vehicle. *ak