Investigations


NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
SERVICE BRAKES, HYDRAULIC
EA11001GENERAL MOTORS CORP.01/05/2011Brake line corrosion failure
 The office of defects investigation (odi) received defect petition dp10-003 on march 2, 2010, requesting the investigation of model year (my) 2003 chevrolet silverado 2500hd 4wd pickup trucks for corrosion failures of the vehicle brake lines.dp10-003 was granted and on march 30, 2010, preliminary evaluation pe10-010 was opened on more than six million model year 1999 through 2003 light trucks and sport utility vehicles manufactured and sold by general motors corporation (gm).on july 2, 2010, odi received gm's response to an information request, which included gm's assessment of the frequency and safety consequences of the alleged defect. gm stated that:(1) the brake system of the subject vehicles is split front/rear and should a brake pipe suddenly fail for any reason, the affected vehicle would be capable of stopping with the pressure supplied by the remaining circuit; (2) the subject vehicles were designed to meet the hydraulic circuit partial failure requirements of federal motor vehicle safety standards 105 and 135, light vehicle brake systems; and (3) should a brake fluid leak occur for any reason, the brake system malfunction indicator lamp (mil) would illuminate and warn the driver before the brake fluid level was low enough to cause a loss of line pressure. of the890 total complaints for brake pipe corrosion identified, 761 were located in salt belt states (connecticut, delaware, district of columbia, illinois, indiana, iowa, maine, maryland, massachusetts, michigan, minnesota, missouri, new hampshire, new jersey, new york, ohio, pennsylvania, rhode island, vermont, west virginia and wisconsin).the complaint rate per 100,000 vehicles sold is significantly higher in the salt belt, 43.0, compared with 3.0 for the remaining states.in approximately 25 percent of the complaints, the brake pipe failure has allegedly occurred suddenly, with no warning to the driver (i.e., no brake warning light), and resulted in extended stopping distances.in 26 of these incidents, the increase in stopping distance that resulted was alleged as a factor in a crash and in 10 others the vehicle was intentionally steered off the road or into another lane of travel in order to avoid a crash.an engineering analysis has been opened for subject vehicles sold or currently registered in salt belt states to further assess the scope, frequency and safety risks associated with sudden failures of corroded brake pipes that can result in decreased brake effectiveness. odi will continue to gather information on subject vehicles outside the salt belt as well.
SERVICE BRAKES, HYDRAULIC - FOUNDATION COMPONENTS - HOSES, LINES/PIPING, AND FITTINGS
EA11001GENERAL MOTORS CORP.01/05/2011Brake line corrosion failure
 The office of defects investigation (odi) received defect petition dp10-003 on march 2, 2010, requesting the investigation of model year (my) 2003 chevrolet silverado 2500hd 4wd pickup trucks for corrosion failures of the vehicle brake lines.dp10-003 was granted and on march 30, 2010, preliminary evaluation pe10-010 was opened on more than six million model year 1999 through 2003 light trucks and sport utility vehicles manufactured and sold by general motors corporation (gm).on july 2, 2010, odi received gm's response to an information request, which included gm's assessment of the frequency and safety consequences of the alleged defect. gm stated that:(1) the brake system of the subject vehicles is split front/rear and should a brake pipe suddenly fail for any reason, the affected vehicle would be capable of stopping with the pressure supplied by the remaining circuit; (2) the subject vehicles were designed to meet the hydraulic circuit partial failure requirements of federal motor vehicle safety standards 105 and 135, light vehicle brake systems; and (3) should a brake fluid leak occur for any reason, the brake system malfunction indicator lamp (mil) would illuminate and warn the driver before the brake fluid level was low enough to cause a loss of line pressure. of the890 total complaints for brake pipe corrosion identified, 761 were located in salt belt states (connecticut, delaware, district of columbia, illinois, indiana, iowa, maine, maryland, massachusetts, michigan, minnesota, missouri, new hampshire, new jersey, new york, ohio, pennsylvania, rhode island, vermont, west virginia and wisconsin).the complaint rate per 100,000 vehicles sold is significantly higher in the salt belt, 43.0, compared with 3.0 for the remaining states.in approximately 25 percent of the complaints, the brake pipe failure has allegedly occurred suddenly, with no warning to the driver (i.e., no brake warning light), and resulted in extended stopping distances.in 26 of these incidents, the increase in stopping distance that resulted was alleged as a factor in a crash and in 10 others the vehicle was intentionally steered off the road or into another lane of travel in order to avoid a crash.an engineering analysis has been opened for subject vehicles sold or currently registered in salt belt states to further assess the scope, frequency and safety risks associated with sudden failures of corroded brake pipes that can result in decreased brake effectiveness. odi will continue to gather information on subject vehicles outside the salt belt as well.

Consumer Complaints


Fail datemilesoccurencesPurchase date
SERVICE BRAKES
03/14/2013129000
 Today while i was at a stop with my truck in gear and the brake pedal depressed with minimal pressure, i heard air release and my brake pedal fully depressed to the floor. my brake lines had ruptured causing brake fluid to spill out and my brakes barely worked at all. i had to push the brake pedal into the floor with excessive effort just to slowly roll to a stop at low speeds. luckily i was just a mile or so away from home and i was able to make the rest of the trip without incident. however, just minutes before the failure i was traveling on the freeway at 65 miles per hour during rush hour. at those speeds it would have been impossible to stop quickly, or at all, if needed had the brake lines had ruptured then. this could have caused a multiple vehicle accident with potential injuries or fatalities. i may not have made it home alive if that were the case which is a very scary thought. this issue really should be addressed.
11/11/20121686131
 Getting ready to leave home and noticed a leak near the left rear tire. i crawled under the truck and noticed a drip from the brake line. at this time, my wife was going to move the vehicle from out in front of the garage and i advised her not to hit the brakes to hard as there was a leak. when she hit the brakes to start the vehicle the petal went to the floor and fluid sprayed everywhere. i feel fortunate it happened when it did versus out on the road. *tr
11/11/2012168613
 Getting ready to leave home and noticed a leak near the left rear tire. i crawled under the truck and noticed a drip from the brake line. at this time, my wife was going to move the vehicle from out in front of the garage and i advised her not to hit the brakes to hard as there was a leak. when she hit the brakes to start the vehicle the petal went to the floor and fluid sprayed everywhere. i feel fotunate it happened when it did versus out on the road.
07/21/20121400001
 Im getting ready for a trip, from texas to ohio in sept. pulling another vehicle. i decided to get the truck ready before such a long trip. it started fine, no signs of problems, i pushed on the brake before changing gears, and my pedal went to the floor. i could hear squirting and air. i knew i had a leak. i investigated the issue and found hydraulic fluid under the driver side seat. i found one of the lines had split above the ehcu unit, spitting fluid all over the under body. this line was severely rusted. the other lines have some surface rust but nothing like this line. it is no longer tubular looking and looks more like a wet stick with a lot of missing branches, and is much larger looking than the others. also, i found a leak on a line that runs to the rear axle, on the driver side frame that was severely rusted like the one described above. im pretty sure this is the line that is split, but its hard to tell, i cant find a diagram to help trace the lines. after investigating the issue, i rechecked my dash lights to see if an abs or a brake light, none are on. i have contacted dealers and brake mechanics for repair, and have to have it towed as there is not enough pressure in the line to stop the vehicle. the truck was purchased in ohio. i would have imagined that they would be coated or stainless since it is a salt belt state, and im not sure why only one line degraded like it did.. this is a 2002 avalanche 1500 4wd with z71 off road package, it is expected to get dirty and wet. i believe better standards are in order to improve safety, and that there should, with this many people affected, definitely be a recall on the lines. had it decided to hold up until my trip, this could have been very disastrous. *tr
07/21/2012140000
 Im getting ready for a trip, from texas to ohio in sept. pulling another vehicle. i decided to get the truck ready before such a long trip. it started fine, no signs of problems, i pushed on the brake before changing gears, and my pedal went to the floor. i could hear squirting and air. i knew i had a leak. i investigated the issue and found hydraulic fluid under the driver side seat. i found one of the lines had split above the ehcu unit, spitting fluid all over the under body. this line was severely rusted. the other lines have some surface rust but nothing like this line. it is no longer tubular looking and looks more like a wet stick with a lot of missing branches, and is much larger looking than the others. also, i found a leak on a line that runs to the rear axle, on the driver side frame that was severely rusted like the one described above. im pretty sure this is the line that is split, but its hard to tell, i cant find a diagram to help trace the lines. after investigating the issue, i rechecked my dash lights to see if an abs or a brake light, none are on. i have contacted dealers and brake mechanics for repair, and have to have it towed as there is not enough pressure in the line to stop the vehicle. the truck was purchased in ohio. i would have imagined that they would be coated or stainless since it is a salt belt state, and im not sure why only one line degraded like it did.. this is a 2002 avalanche 1500 4wd with z71 off road package, it is expected to get dirty and wet. i believe better standards are in order to improve safety, and that there should, with this many people affected, definitely be a recall on the lines. had it decided to hold up until my trip, this could have been very disastrous.
SERVICE BRAKES, ELECTRIC
08/03/2011141574
 Recently my 2002 chevrolet avalanche has begun to shut off while driving which causes the vehicle to lose power. another important safety issue, the brakes began to press all the way to the floor while braking. on august 3, 2011 while my son was driving the vehicle approaching a stop light, he pressed the brakes which went to the floor and rear ended vehicle in front that was making a turn. the front bumper is now damaged ( t-boned) and the air bags did not deploy. i'm not very pleased that i never received any notices about the braking system. i can't afford to make monthly payments and still have to pay costly maintenance fees. i can not afford to jeopardize my life and my family, especially my granddaughter. something has to be done about these safety issues: braking, cutting off while driving and no deployed air bags.
06/09/201192448
 07/12/10 brakes failed on 2002 chevrolet avalanche...brakes went to the floor and left lane was free of traffic or i would have rear ended cars in front of me stopped at red light. rusted brake line was replaced at brake specialist for $573.55. 06/09/11 as i approached red light, brakes failed, pedal to the floor stopped just inches from stopped car in front of me. took the avalanche to repair shop tx. they currently have the avalanche, four rusted brake lines...$1700 to replace. i have googled this rusted brake issue with the avalanches and it seems many other owners are having the same problem.
04/23/201084000
 The abs kick in while turning at low speed.
01/18/200582000
 Dash light don't work. dimmer switch very hot to the touch
11/10/20091200001
 2002 avalanche 1500, abs would activate when coming to a slow stop. dealer said it was probably the speed sensors, recall was already done so they wouldn't do it again. that is not right! i don't care how many times they have to fix it, if safety parts are failing, they need to replace them! long story short... i replaced the sensors, didn't work. i replaced the whole bearing/hub assembly which came with pre-installed sensors. fixed! *tr
SERVICE BRAKES, HYDRAULIC
11/18/201152000
 Tl-the contact owns a 2002 chevrolet avalanche 1500. the contact stated that he attempted to brake, but the brake pedal depressed to the floor. the contact down shifted and the vehicle coasted to a stop. the vehicle was taken to a dealer and a five foot section of the brake lines was replaced due to corrosion. the contact was also informed that the remainder of the brake lines would need to be replaced due to rust and corrosion. the failure and current mileages were 52,000. sm.
10/04/201187894
 Corrosion of hard brake line from the master cylinder to the rear distribution module resulted in loss of braking capacity when the brake line failed resulting in fluid leakage.
12/22/200867000
 Coming to a stop and brakes went to the floor abs light came on , found hole in brake line lines rusted all through out the vehicle . i almost hit a women on feb 6 2010 another hole was found in the line on sept 21 2011 brakes did it again to the floor it my emergency brake to stop 2 different lines have holes in them am trying to replace as much as i can. there is a box under the body that my brake lines go into they are rusted really bad to im not sure what the box is for i have had a lot of brake problems.this truck has been not driven for months at a time due to brake problems thank you
08/02/201183000
 @002 chevy avalanche, rusted brake lines, brake line burst(failure), loss of braking
07/12/201092448
 Brakes failed on 7/12/10 almost rear ended car before came to stop by veering into left lane to avoid car stopped at red light. repair shop replaced rusted brake line. again, 6/9/11, went to brake for red light, brake pedal went to the floor and stopped just before rear ending car stopped at red light. repair shop says rusted brake lines!
06/03/201176000
 Tl* the contact owns a 2002 chevrolet avalanche 1500. the contact was driving approximately 30 mph when the brake warning light illuminated and the brake pedal was depressed to the floor board, reducing braking pressure. the contact stated that the failure was constant and the brake pedal needed to be depressed to the floor in order to stop the vehicle. the vehicle was not taken to a dealer for diagnostics or repairs. the contact referenced an open investigation relating to the failure under nhtsa action number: ea11001 (service brakes, hydraulic service brakes, hydraulic:foundation components:hoses, lines/piping, and fittings). the approximate failure mileage was 76,000.
06/03/201176000
 Tl- the contact owns a 2002 chevrolet avalanche. while driving approximately 30 mph the brake warning light illuminated on the instrument panel and the brake pedal dropped to the floor board reducing the braking pressure. the contact stated the failure was constant and the brake pedal needs to be depressed to the floor in order to stop the vehicle.the vehicle was not taken to a dealer for diagnostics. the vehicle was not repaired. there was an open investigation under nhtsa action number: ea11001 (service brakes, hydraulic service brakes, hydraulic:foundation components:hoses, lines/piping, and fittings) that may be related to the failure. the approximate failure mileage was 76,000. ds
05/13/201186830
 Tl*the contact owns a 2002 chevrolet avalanche 1500. the contact stated that the vehicle would not start immediately; however, after several attempts, the contact was able to turn the vehicle on. the failure recurred the following day. she purchased a battery but the vehicle was making an unusual noise. she also noticed that the abs light illuminated on the instrument panel. she turned the vehicle off but the noise continued. when she tried to start the vehicle the following day, the battery was dead. the dealer advised her to unplug the abs motor. the vehicle was taken to an authorized dealer who stated that the abs motor needed to be replaced. the vehicle had not been repaired. the manufacturer stated that the vehicle was not included in recall 05v379000 (service brakes, hydraulic:antilock). the current mileage was 86,835. the failure mileage was 86,830.
05/13/201186830
 Tl-the contact owns a 2002 chevrolet avalanche 1500. the contact stated that the vehicle would not start when she attempted to start it. after several attempts, the vehicle was able to be started. the failure occurred again the next day. she purchased a new battery but the next day she noticed that the vehicle was making a funny noise. she also noticed that the abs light illuminated on the instrument panel. she turned the vehicle off but the noise continued. when she tried to start the vehicle the next day, the new battery was completely dead. the dealer, when called, advised her to unplug the abs motor. the vehicle was taken to an authorized dealer who stated that the abs motor needed to be replaced. the vehicle had not been repaired. the manufacturer stated that the vehicle was not included in recall 05v379000 (service brakes, hydraulic:antilock). the current mileage was 86,835. the failure mileage was 86,830-bk
02/20/2002160000
 2002 chevrolet avalanche z-71, brake lines rusty to the point of failure at anytime, spongey pedal, and difficulty stopping. at present time have not repaired due to extreme cost. if there is a casatrophic failure of the brake system there will be a massive class action law suit (if my family and i survive).
02/06/201189580
 I expeienced a brake line failure on my 2002 chevrolet avalance 1500 4x4 while vactioning in florida. on sunday, february 6, 2011, i noted that the brake pedal fely spongy. upon investigation, i noted a leakage behine the driver side front tire. when i checked the brake fluid reservoir it was below the normal level. an inspection of the brake lines indicated severe rust and corrosion. i had to drive to the nearest repair shop and rent a car until the repair was complete.
09/25/2008125000
 I wanted to add to the complaint about brake eriosion on 2002 chevy avalanche. my front brake line blew out when braking. i nearly missed the car in front of me that was stopping when i drove off the side of the road. i've also had to replace nearly all my brake lines due to leaks. i live in up-state new york.
10/17/201093000
 Re: chevrolet avalanche break failures... the break lines on chevrolet trucks are made of a material that is not rust resistant and leads to break failures such as it did on my 2002 avalanche... although my failure happened at low speed, it is a definate safety concern for owners of these gm products. hundreds of complaints are listed on various web sites detailing this problem, one that gm will not hone up to because the repair bill to replace the entire break line system costs owners over $800.00 at a gm dealer. please look into this gm failure to put rust resistant materials on this very important part of any vehicle.
07/27/201057490
 On 07/27/2010 i was driving my chev avalanch, 2002, with 57000 miles on it. i came to a stop sign and the brakes failed. i investigated and the drivers side rear hard brake line had rusted through. i replaced both rear lines, bled the brakes drove the truck to test the brakes and the drivers front hard line blew out, it had an 1/8 inch hole rusted in it.
08/16/2010120000
 The brake lines on my 2002 chevrolet avalanche are severely corroded (rusted). i already had a ten-foot section of the tubing replaced this summer. since a 'hard stop' last week, my brake pedal now has a soft mushy feel, and braking distances are longer. another section of the brake lines seems to have 'burst' and is leaking brake fluid. i'm taking it back to the shop to have the entirety of the brake lines replaced. hoping i'll eventually be able to get the cost of this repair covered by gm, as i don't think these should fail (ever), even after the warranty has expired.
08/16/2010105500
 Truck sitting in yard and brake line failed
04/21/2010931581
 I am currently having a problem with my 2002 chevrolet avalanche as to unwarranted abs activation. the vehicle is unable to stop a low speeds or hesitates at 5 mph coming to a stop. i began to have this problem about a week ago, on or about april 14th, 2010. i conducted a search of your web site and saw that there has been previous complaints from 2005. i contacted chevrolet at the number provided in your recall bulletin # 05v-379. when i spoke to a customer service representative they told me my vin # did not qualify for the recall. chevrolet will not honor any repair to this vehicle which i believe clearly falls within the make/model/year. i plan to have the repairs made, and file suit against chevrolet for the cost of those repairs. *tr
04/09/201059000
 Brake line burst near abs module under truck
12/27/2009134700
 At the end of december, we were traveling down the highway at approximately 55 mph. i went to apply my brakes and the pedal went completely to the floor. i realized that i had no brakes. i down shifted and coasted to the nearest garage. after a thorough investigation, the mechanic informed me that the entire brake system needed replaced. at a hefty price, i replaced it all. the old parts are not available.
03/23/201084000
 Nhtsa action # pe05020, nhtsa recall # 05v379000, gm corp, service brakes, hydraulic, antilock. this problem persists in my 2002 chevy avalanche. the recall only temporarily fixed problem. i am requesting nhtsa extend recall to repair ongoing problem. this problem may cause loss of life. i have notified gm and expect a follow up by nhtsa.
05/28/2009445001
 During an emergency braking condition, the front brake line failed causing loss of brakes. found all brake lines corroded to point of possible failure under same conditions. truck has only 44,500 miles on it. also found extensive corrosion throughout frame. truck had additional undercoating installed by dealer(marchese chevrolet in ny). dealers reply to condition, yeah we have had several avalanches and cavaliers with the same problem. it is not known if the problem is substandard steel or possibly a reaction with the undercoating. vehicle is not being used at present time. vehicle is a 2002 chevrolet avalanche purchased new 12/2002. additional issues with brakes, dealer recall on rotors 22,000 miles all 4 replaced, rotors and pads replaced by local shop with 42,000 miles, all 4 in need of replacement again. *tr
05/28/2009385001
 2002 chevrolet avalanche - brake line rusted through after only 38,000 miles resulting in no brakes while going down hill. luckily i was able to avoid hitting any other vehicles. downshifted the transmission and used the parking brake to eventually stop the vehicle. i've now read several hundred other reports of the same problem. gm should be made to replace all brake lines on all chevrolet avalanches with stainless steel lines. this is an extremely dangerous situation which only shows up when you try to use the brakes - which is obviously when you most need them!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! *tr
04/01/20091201341
 2002 chevrolet k1500 avalanche 4wd activates antilock brakes while completing a stop at low speeds (less than 5mph). this malfunction occurs every time the vehicle is driven, often every time the vehicle comes to a complete stop. the activation of the abs system has the undesired effect of greatly lengthening the stopping distance in an uncontrolled manner. in effect, the vehicle is not under control when approaching a stopped vehicle in traffic, intersection, pedestrian, parking, etc. this is a very hazardous malfunction of the abs system. this particular truck was recalled and repair was attempted by a chevrolet dealership a few years ago. this previous dealership repair of the uncontrolled abs braking was not sufficient as the abs malfunction has returned on this vehicle. on 4/1/09 the chevrolet dealership has refused to repair my current abs malfunction condition, stating that gm will only do the repair once. the dealership repair did not work on my 2002 avalanche, and now i am stuck with a vehicle that is a safety hazard on the roads due to uncontrolled releasing of brake pressure at low speeds. please give me direction of what action i can take. thank you. *tr
12/27/2008550001
 02 chevy avalanche electronic brake control module is defective and no longer under warranty. gm has had documented problems with the abs on the '02 avalanche but so far has only issued a recall for northern states, blaming the problem on road salt rather than the obvious design or manufacture defect. road salt didn't cause this abs failure because i live in florida. the recall should be extended to the whole u.s. this is a safety issue that nhtsa should address with a mandatory recall for all '02 chevy avalanches. gm refuses to acknowledge that it is a safety problem rather than a warranty issue. i did a 360 on a major interstate due to this and should be addressed before it kills someone. *tr
12/14/2008139000
 Tl*the contact owns a 2002 chevrolet avalanche 1500. when the contact turned off the vehicle, she heard a noise in the abs. the battery was drained and the system no longer worked. the dealer stated that there was abs failure. the contact stated that the recall on the abs should be extended to all chevrolet vehicles in all states, not just the winter states. the vehicle is currently being repaired at the dealer. the failure mileage was 139,000.
SERVICE BRAKES, HYDRAULIC - ANTILOCK
11/13/2009740001
 I own a 2002 chevy avalanche, and i am having daily problems with the anti lock braking system activating inappropriately at slow speeds and during slow turns. it started happening occasionally some 2-4 years ago, and has progressed to a daily occurrence. i just had major work done replacing my wheel bearings, rotors, pads, shocks, and struts, but the problem did not go away its still occurring. chevrolet is away of the defect, but not enough owners have complained or have been injured for them to make it worth their time to fix or contact owners of a certain potential problem. *tr
03/10/20071
 Unwanted antilock brake system (abs) activation. *tr
03/27/2007750001504/02/2006
 Tl*the contact owns a 2002 chevrolet avalanche 1500. while the brake pedal was depressed, the abs activated. the dealer stated that the vin was not included in nhtsa campaign id number 05v379000 (service brakes, hydraulic: antilock). the contact is responsible for the repair costs. the current and failure mileages were 75,000.
10/03/200766000105/11/2002
 1. use of brakes at low speed 2. unwanted abs activation and extended stopping distances during low-speed braking 3. chevrolet refuses to correct problem related to recall 05v379000. *jb
08/02/2007102800101/15/2007
 2002 chevy avalanche 1500 4x4 z71 corrosion in the front wheel bearing hub contaminated the tone ring on the speed sensor causing the brakes not to work correctly. lock up or not work at all very dangerous situation. i replaced the hud and it cured the problem appears that the moisture causing the corrosion got thru at the speed sensor plug. i see canada already has a recall on this why is the us taking so long to implement the recall. does some one have to die for it to be an important safety issue. *tr
SERVICE BRAKES, HYDRAULIC - FOUNDATION COMPONENTS - HOSES, LINES/PIPING, AND FITTINGS
11/23/200793800107/01/2005
 Tl*the contact owns a 2002 chevrolet avalanche 1500. while driving 55 mph, the vehicle would not stop. the brake pedal extended to the floor when it was depressed. the contact had to downshift and cruise to a stop. as of november 26, 2007, the dealer had not inspected or repaired the vehicle. the contact felt that the rusted brake lines caused the failure. the current and failure mileages were 93,800. updated 0310/08. *lj