Unwanted ABS activation and extended stopping distances during low-speed braking.

- Pandora, OH, USA

The brake lines were heavily corroded and starting to leak fluid. They needed to be replaced from the master cylinder back to all four wheels. This was confirmed by dealer inspection. This premature corrosion is a serious safety problem. This is a personal use 2002 pick up truck with only 66,300 miles.

- Newtown, CT, USA

The contact owns a 2002 Chevrolet Silverado. The contact was driving 25 mph and approaching a stop. The brake pedal became extremely stiff and resistant to the contact's attempts to brake. The failure would cause an increase in braking distance and time that it took to stop the vehicle. The ABS warning light was also illuminated. The contact stated that the brake pedal would intermittently vibrate and the contact would have to repeatedly pump the brakes in order to stop the failure. The brake pads and rotors were replaced by an independent repair facility yet the ABS warning light remained illuminated. The failure recurred within three days of the repair. The contact stated that he did not feel safe driving the vehicle to an authorized dealer which was several miles from his residence. The manufacturer was contacted three times and would not provide any assistance. The vehicle was not repaired. The failure mileage was 104,000.

- Oxford, WI, USA

Brake lines to rear wheels failed with mild break application. This was due to rusty break lines. There were no brakes at the application of the pedal. This is not a isolated case, dealers have seen many cases of this problem. Today as I had my truck at the dealer another Chevy truck came in with the same problem.

- Kennett Square, PA, USA

Sudden total brake failure (all 4 wheels) due to rusted under body brake lines. Service center is replacing all old lines from master cylinder to ABS module and onto wheel cylinders. Samples of old rusted lines are being retained.

- Raleigh, NC, USA

2002 Chevy Silverado brake line burst during normal operating condition. Resulted in truck going through intersection with red light. Mechanic attributed to rust on brake lines.

- Pasadena, MD, USA

Brake lines rusted through on a 2002 Chevrolet Silverado 1500 extra cab 4X4. Luckily no accident resulted with the brake failure. Called Chevrolet corporate to check on recall. Nothing noted.

- New Salisbury, IN, USA

Have a 2002 Silverado with 46,000 miles and in June 2010 experienced a major brake failure when the brake lines near the frame rail brake/ABS controller rusted away. When trying to stop the brake pedal went to floor, was near home and drove the rest of the way. The next day the brake warning light was on, the fluid had leaked out and I discovered the problem - the rusted lines. A $1000 of brake work to correct the brake lines, that is replace them and new front brakes because the calipers had also rusted so badly they couldn't bleed the brakes. This is not acceptable for a modern vehicle to have safety parts rust so badly at such low mileage.

- Upper Marlboro, MD, USA

The contact owns a 2002 Chevrolet Silverado 1500. The contact stated that when pulling from the driveway and attempting to depress the brake pedal, the vehicle continued moving and crashed into a fence. There were no injuries. No police report was filed. The vehicle suffered damages to the front end and bumper. The vehicle was taken to an authorized dealership where the contact was informed that the brakes needed to be replaced; the repair was performed at that time. When leaving the dealership, the failure occurred again and the vehicle was taken to another mechanic who stated that the wheel sensor needed to be replaced; the repair was performed at that time. The vehicle continued having problems and would not stop when the brake pedal was depressed. The mechanic was working on the vehicle at the time of the complaint but still could not find the problem. The VIN was unavailable at the time of the complaint. The current and failure mileages were approximately 43,000.

- Beckley, WV, USA

I drive a 2002 Chevy Silverado 1500. Yesterday (5/14/10) I was applying my brakes to come to a sudden stop when someone cut out in front of my truck. I lost all braking ability when I applied my brakes to stop. Luckily I was able to steer away from the on coming car and ended up on the side of the road. I got out of my truck to check my brakes when I noticed a puddle of brake fluid under the front of my truck. Upon closer examination I noticed excessive rust on the brake line and brake fluid was free flowing from a rupture in the brake line that was heavily corroded.

- Douglas , MA, USA

I saw the newspaper article on the possible brake failure on 99-03 pickup trucks. This happened to my son in my 2002 Chevy Silverado in my driveway which is about 100 feet long. He pushed on the brakes and the pedal went to the floor. Luckily he was going slow. There was brake fluid in the driveway. I was outside at the time and got in and pumped the brakes. None. I had to have it towed to a repair shop and they replace a defective brake line. Your article has made me fearful for my family.

- Lake View, NY, USA

March 27, 2010 rear driver side brake line burst on 2002 Chevy Silverado while on highway. When brought in for repair 2 new calipers were needed due to extensive corrosion. Repairs came to $617.

- Wethersfield, CT, USA

Corroded brake lines caused the failure of both front and rear brakes at the same time. Inoperable rear emergency brakes provided no emergency stopping ability. Replaced brake lines. Emergency brake not repaired. I understand that trucks with manual transmissions were recalled for emergency brake defect correction, but trucks with automatic transmissions were not eventhough they have the same emergency brake system. My vehicle has an automatic transmission. Not certain when emergency brakes became inoperable, but my guess is around 2004 or 2005, with 60K to70K miles. Brake line rupture was in 2009 at 156K miles.

- Aliquippa, PA, USA

Rupture of hydraulic brake lines including anti lock portion, total loss of braking.

- Liverpool, NY, USA

The contact owns a 2002 Chevrolet 1500. While driving at approximately 5 mph, the contact noticed that the vehicle continued moving when he depressed the brake pedal. The vehicle was taken to an authorized dealership but the dealer could not duplicate the problem. A local mechanic replaced the brake pads and rotors but the contact was still experiencing the same failure. The contact had not called the manufacturer at the time of the complaint. The failure mileage was approximately 20,000. The current mileage was approximately 84,000. Updated 3/31/15 updated 04/07/15

- Nashville, AR, USA

Brake failure, hydraulic steel brake lines rusted and burst when brakes were applied resulting in total loss of brakes. All steel brake lines had to be replaced because they were all severely rusted costing $1400.

- Higganum, CT, USA

The contact owns a 2002 Chevrolet Silverado 1500. The contact was driving approximately 5 mph when the brakes failed to engage. The brake pedal was engaged repeatedly before in order to stop the vehicle. The failure occurred whenever traveling between 5 to 10 mph. The vehicle had not been repaired at the time of the complaint. The failure mileage was 21,500. The current mileage was 23,200. Updated 06/03/10 updated 06/07/10

- Cromwell, CT, USA

While attempting to stop for a red light, the brake pedal went to the floor and I went through the light. After getting the truck stopped with the emergency brake, I found brake fluid leaking from under the truck from corroded brake lines. I made temporary repairs to the leaking lines and returned to my home. I checked online about this problem and found it seems to be a common problem. I also found from forums GM knows of this problem and simply says to live with it. So far I haven't done anything to fix the problem as GM doesn't offer any replacement parts.

- Batavia, OH, USA

Rusted brake lines possible brake failure.

- Rochester, NY, USA

This is a follow up complaint to one I called in to the NHTSA to report this problem. I too had a brake line rupture on my 2002 Chevy pickup and my brakes fail as a result of corroded brake lines. This truck had already been recalled due to the wheel speed sensor failing at low speed which they GM) also attributed to corrosion. And just last month they failed because of the line corroding and rupturing. I attempted to come to a stop at an intersection when I applied the brakes and the brake pedal went all the way to the floorboard. I eventually stopped just short of the intersection and was able to drive the truck to a service station. I got out of the truck and saw the brake fluid leaking out of the ruptured brake line beneath the driver's side door. I took the truck in and was informed the brake lines were rotted out and would have to be replaced. $1800 dollars later I got my truck back. Let's see how long they last this time..

- Chester, NY, USA