2002 Chevrolet Avalanche

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.ODI's and GM's analysis indicates that 85 percent of the complaints occurred on vehicles used primarily in States that use salt on the roads during Winter months (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).Overall the complaint rates per 100,000 vehicles for Salt Belt States is 43.0 and Non-Salt Belt is 3.0.In approximately 25 percent of the complaints the brake pipe failure occurred suddenly, with no warning (i.e., no MIL, Brake Fluid Loss Warning), and resulted in extended stopping distances.In 30 of these the increase in stopping distance that resulted was a factor in the 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.This investigation has been upgraded to an Engineering Analysis (EA11-001) 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.

THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE06-016) ON MAY 4, 2006 BASED ON ELEVEN VEHICLE OWNER QUESTIONNAIRES (VOQS) AND EARLY WARNING (EWR) DATA ALLEGING SUDDEN ENGINE SHUTDOWN WHILE DRIVING AS A RESULT OF CRANK POSITION SENSOR FAILURES IN MY 2001-2002 GENERAL MOTORS C/K PLATFORM VEHICLES EQUIPPED WITH 8.1L ENGINES.IN RESPONSE TO AN INFORMATION REQUEST LETTER SENT BY ODI, GENERAL MOTORS (GM) PROVIDED OWNER COMPLAINT INFORMATION, FIELD REPORTS AND WARRANTY CLAIM DATA BASED ON A POPULATION OF 108,338 VEHICLES. THE DATA WAS CATEGORIZED BY ENGINE STALLS WHILE DRIVING, ENGINE STALLS WITH AN UNKNOWN DRIVING CONDITION, NO START CONDITIONS AND CLAIMS WHERE IT WAS INDETERMINATE IF AN ENGINE STALL OCCURRED WHILE DRIVING.GENERAL MOTOR'S RESPONSE INCLUDED 1,213 OWNER COMPLAINTS AND FIELD REPORTS OF WHICH 289 WERE CATEGORIZED AS ENGINE STALLS WHILE DRIVING ALLEGEDLY CAUSED BY CRANK POSITION SENSOR FAILURES. GENERAL MOTORS ALSO SUBMITTED WARRANTY CLAIMS FROM ITS REGULAR WARRANTY (5 YEARS/50,000 MILES) AND FROM ITS EXTENDED WARRANTY DATABASE. FROM THE REGULAR WARRANTY DATABASE THERE WERE 3,140 CLAIMS OF CRANK POSITION SENSOR REPLACEMENT OF WHICH 147 CLAIMS WERE FROM CONSUMERS ALLEGING ENGINE STALL WHILE DRIVING.GM STATED THAT 2,841 OF THE CLAIMS WERE INDETERMINATE IF AN ENGINE STALL OCCURRED WHILE DRIVING.FROM ITS EXTENDED WARRANTY DATABASE, GM SUBMITTED 1,561 CLAIMS OF CRANK POSITION SENSOR FAILURE THAT IT ALSO STATED WERE INDETERMINATE AS TO WHETHER AN ENGINE STALL OCCURRED WHILE DRIVING.IN TOTAL, GM REPORTS 4,701 CLAIMS OF CRANK POSITION SENSOR FAILURE COMBINING REGULAR WARRANTY AND EXTENDED WARRANTY.SIMILAR TO GM'S STATISTICAL ANALYSIS, ODI'S ANALYSIS SHOWED THAT THE FAILURE RATE FOR WARRANTY CLAIMS OF ENGINE STALL WHILE DRIVING AT THREE YEARS IN SERVICE IS LOW (LESS THAN 1%).HOWEVER, FURTHER ANALYSIS DETERMINED THAT THE MY 2001 VEHICLE BUILD PERIOD FROM MAY 2000 THROUGH OCTOBER 2000 HAD SIGNIFICANTLY HIGHER (MORE THAN FOUR TIMES) CRANK POSITION FAILURE RATES IN BOTH CONSUMER COMPLAINT DATA AND WARRANTY CLAIM DATA THAN IN THE BUILD PERIOD FROM NOVEMBER 2000 THROUGH JULY 2001.ADDING THE CLAIMS OF KNOWN ENGINE STALL WHILE DRIVING AND CLAIMS WHERE ENGINE STALL WAS INDETERMINATE, THE FAILURE RATE AT THREE YEARS IN SERVICE FOR THIS POPULATION IS OVER 6%.AN ENGINEERING ANALYSIS (EA06-016) HAS BEEN OPENED TO FURTHER ASSESS THE FREQUENCY AND POTENTIAL SAFETY CONSEQUENCES ASSOCIATED WITH THE ALLEGED DEFECT IN VEHICLES BUILT FROM MAY 2000 THROUGH OCTOBER 2000.

ODI'S REVIEW OF COMPLAINT DATA RECEIVED SINCE THE CLOSE OF EA04-011 REVEALED NO INDICATION THAT THE INVESTIGATION SHOULD BE RE-OPENED.MORE DETAILS CAN BE FOUND IN THE FEDERAL REGISTER NOTICE ENCLOSED IN THE DP05-009 PUBLIC FILE.ODI RESERVES THE RIGHT TO REOPEN THE INVESTIGATION IN THE FUTURE SHOULD CONDITIONS WARRANT.

IN A LETTER DATED AUGUST 29, 2005, GM NOTIFIED ODI THAT IT WAS RECALLING CERTAIN MODEL YEAR 1999 THROUGH 2002 C/K PICKUP TRUCKS AND SPORT UTILITY VEHICLES TO CORRECT A PROBLEM WITH ANTI-LOCK BRAKE SYSTEM (ABS) WHEEL SPEED SENSOR CORROSION THAT MAY RESULT IN UNWANTED ABS ACTIVATION AND EXTENDED STOPPING DISTANCES DURING LOW-SPEED BRAKING (RECALL 05V-379).GM'S RECALL COVERS APPROXIMATELY 804,000 VEHICLES CURRENTLY REGISTERED IN THE FOLLOWING 14 SALT-BELT STATES:CONNECTICUT, ILLINOIS, INDIANA, MASSACHUSETTS, MAINE, MICHIGAN, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, AND WEST VIRGINIA.THE RECALL PROCEDURE WILL INVOLVE REMOVING THE SENSOR, CLEANING THE MOUNTING SURFACE, APPLYING A RUST INHIBITOR (ZINC-X) TO THE SURFACE, AND REINSTALLING THE SENSOR.IF NECESSARY, THE SENSOR WILL BE REPLACED. THE POPULATION AND FAILURE REPORT DATA GIVEN IN THIS RESUME ARE FOR THE FULL REGION THAT HAS BEEN CONSIDERED BY ODI AS THE SALT-BELT.THAT INCLUDES DELAWARE, IOWA, MARYLAND, MINNESOTA, MISSOURI, WISCONSIN AND THE DISTRICT OF COLUMBIA IN ADDITION TO THE 14 STATES INCLUDED IN 05V-379.THE STATES COVERED BY GM'S RECALL HAVE THE HIGHEST INCIDENT RATES FOR THE SUBJECT CONDITION, ACCOUNTING FOR 91% OF THE INCIDENTS, BUT ONLY 24% OF SUBJECT VEHICLE SALES IN THE UNITED STATES.ODI'S ANALYSIS DETERMINED THAT 840 OF THE COMPLAINTS, 244 OF THE CRASHES, AND 16 OF THE INJURIES IDENTIFIED IN THIS INVESTIGATION OCCURRED IN THOSE STATES.THE RESULTING INCIDENT AND CRASH RATES ARE 96.2 AND 28.0 PER 100,000 VEHICLES RESPECTIVELY (NOTE:RATES ARE BASED ON VEHICLE SALES, NOT REGISTERED VEHICLES). THE CORRESPONDING NUMBERS IN THE EXCLUDED PORTIONS OF THE SALT-BELT ARE 399,000 VEHICLES, 81 INCIDENTS (20.3 PER 100,000 VEHICLES), 3 CRASHES, AND NO INJURIES.THE STATISTICS IN THE REMAINING 30 STATES ARE 2,406,000 VEHICLES, 168 INCIDENTS (7.0 PER 100,000 VEHICLES), 31 CRASHES, AND ONE INJURY.GM AND ODI ARE CONTINUING TO MONITOR THE PROBLEM EXPERIENCE IN STATES THAT ARE NOT INCLUDED IN THE RECALL.GM WILL PROVIDE ODI WITH UPDATED COMPLAINT, FIELD REPORT, AND WARRANTY DATA IN NOVEMBER 2005.ODI AND GM WILL REVIEW THAT DATA AND ASSESS THE APPROPRIATENESS OF THE CURRENT SCOPE OF THE RECALL AT THAT TIME.

The contact owns a 2002 Chevrolet Avalanche. The contact stated while attempting to stop the vehicle, the brake pedal was firm, and vehicle kept accelerating unintendedly. Several warning lights were illuminated. The vehicle was taken to an independent mechanic to be diagnosed. The contact was informed that the failure was due to a faulty ABS module. The vehicle had not been repaired. The manufacturer was made aware of the failure and determined that the vehicle was not included in a recall because he was not located in a salt State. The failure mileage was unknown.

NHTSA ID

11554315

Incident

Nov 7, 2023

The contact owns a 2002 Chevrolet Avalanche. The contact stated that while driving at an undisclosed speed, the ABS and oil warning lights illuminated. Additionally, the speedometer, the 4-wheel drive function, parking brake, and headlights failed to operate as needed. The instrument panel light failed to illuminate, the gear shifter did not display the selected gear, the sub-frame was corroded, and the wheel hub bearing assembly was fractured. The vehicle was not diagnosed nor repaired by an independent mechanic or dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 142,000.

NHTSA ID

11451861

Incident

Nov 1, 2020

Mileage

142,000 mi

BRAKE LINES ARE MADE OUT OF DEFECTIVE MATERIALS GM KNOWS THEY HAVE A PROBLEM THE LINES RUST OUT PREMATURELY . THE FIRST ONE BLEW OUT I WAS BACKING IN A PARKING SPACE PEDAL WENT TO THE FLOOR. THE SECOND ONE BLEW AT A TRAFFIC LIGHT PUSHED ON THE BRAKE WENT THRU THE RED LIGHT DODGED TRAFFIC .THE THIRD ON THE INTERSTATE TRAFFIC WAS STOPPING SUDDENLY PUSHED ON THE PEDAL ANOTHER BRAKE LINE BROKE WENT TO THE FLOOR AND I MANAGED TO HIT THE MEDIAN CROSS THE MIDDLE AND GET IT STOPPED BEFORE A HEAD ON COLLISION WITH THE TRAFFIC HEADING THE OTHER DIRECTION ON INTERSTATE 81 . THE REST OF THE UNDER SIDE IS RUST AND CORROSION FREE ONLY THE BRAKE LINES ARE RUSTED OUT ! .THAT BEING SAID GM HAS A REPAIR KIT WITH COATED LINES THEY ALWAYS HAVE IN STOCK BECAUSE THEY KNOW ITS A MAJOR PROBLEM !!! I GOT A REPAIR ESTIMATE FROM MY LOCAL DEALERSHIP $1580.00 I AM REPLACING ALL STEEL LINES . PLEASE MAKE THEM RECALL THIS IS GOING TO KILL SOMEONE

NHTSA ID

10816904

Incident

Dec 26, 2015

Mileage

7,900 mi

WHEN TRAVELING AT LOW SPEEDS, >5MPH, THE ABS ACTIVATES AND VEHICLE CONTINUES ON TO THE POINT OF ENTERING TRAFFIC. THIS OCCURS FREQUENTLY AND WITHOUT WARNING, AT STOP SIGNS AND EVEN JUST PULLING OUT OF PRIVATE DRIVEWAY INTO TRAFFIC. MY LOCAL MECHANIC RAN A DIAGNOSTIC TEST AND INDICATED THAT A FRONT SPEED SENSOR WAS AT FAULT. AFTER INVESTIGATING NUMEROUS SITES, I FOUND THAT THERE WAS A RECALL ISSUED FOR THE EXACT PROBLEM ON THE '02 AVALANCHE AS WELL AS OTHER SIMILAR CHASSIS TRUCKS FROM '99-'02. AND THESE WERE INCLUDED IN A RECALL OF OVER 1,353,700 TRUCKS UNDER THE NHTSA CAMPAIGN # 05V379000. THE REPORT STATED TO CONTACT GM AND REQUEST AUTHORIZATION FOR THE RECOMMENDED REPAIR. WHEN I DID THAT, THE REPRESENTATIVE STATED THAT THERE WERE NO OPEN RECALLS ACCORDING TO THE VIN. HOW DOES GM DETERMINE WHICH VIN IS AFFECTED? IS THE NHTSA MONITORING GM'S SELECTION PROCESS? I'VE OWN THE VEHICLE SINCE 6/05, AND THE ABOVE RECALL WAS INITIATED 9/05, BUT I'VE NEVER RECEIVED ANY TYPE OF NOTICE THAT MY VEHICLE MAY OR MAY NOT BE AFFECTED AND TO BRING IT TO A GM DEALER FOR INSPECTION. I'VE HAD ONE HUB ASSEMBLY REPLACED YEARS AGO AT MY OWN EXPENSE, (I WAS TOLD I HAD A BAD BEARING BUT THEY HAD THE REPLACEMENT PART ONLY CAME ASSEMBLED AS THE BEARING, HUB AND SENSOR). THE DESIGNER MUST ALSO HAVE BEEN THE SUPPLIER. IT'S GOOD THAT THERE IS THE NHTSA TO TRY AND KEEP THESE MANUFACTURERS ACCOUNTABLE FOR THE SAFETY OF THE CARS THEY PRODUCE, BUT WITH MORE AUTOMATION IN THE INDUSTRY TO CUT COSTS, YOU NOW HAVE 1 WORKER OVERSEEING WHAT IT TOOK 10 TO DO. MORE AND MORE MISTAKES ARE BOUND TO HAPPEN. OUR SAFETY IS WORTH MORE THEN THEIR CORPORATE JETS AND LAVISH LIFESTYLES.

NHTSA ID

10761430

Incident

Jul 30, 2015

Mileage

86,000 mi

WHILE DRIVING AT 65 MPH THE ENGINE CUT OUT. COULD BE THE CRANKSHAFT POSITION SENSOR. THE TRUCK IS A 2500 WITH AN 8.1L ENGINE. SIMILAR ISSUES THAT THE 2001 WAS RECALLED FOR. SAME ENGINE AND CPS AS THE 2001 BUT NOT INCLUDED IN THE ORIGINAL RECALL. THIS HAS HAPPENED SEVERAL TIMES AT VARIOUS SPEEDS.

NHTSA ID

10746261

Incident

Aug 3, 2015

Mileage

90,000 mi

WHILE DRIVING MY TRUCK AND TOWING A TRAILER, I LOST ALMOST ALL MY BRAKING POWER. HAD TO DOWN SHIFT AND USE THE EMERGENCY BRAKE TO STOP. FOUND THAT A BRAKE LINE FROM THE MASTER CYLINDER TO THE ANTI-LOCK BRAKE MODULE (WHICH IS MOUNTED UNDER THE DRIVERS SEAT, GREAT PLACE) HAD RUSTED THROUGH AND BLEW OUT. FOUND ALL THE BRAKE LINES ARE SEVERELY CORRODED IN THIS AREA AND NEED TO BE REPLACED. LOOKS LIKE GM USED INFERIOR METAL BRAKE LINES IN CONSTRUCTING THE VEHICLE AND LOCATED THE ANTI-LOCK BRAKE MODULE IN AN AREA THAT GETS SEVERE EXPOSURE TO THE ELEMENTS. THE VEHICLE WAS TOTALLY RENDERED UNSAFE WITH THE RUPTURE OF ONE BRAKE LINE, WHICH INDICATES THE SYSTEM AS A WHOLE IS A FAULTY DESIGN. I WAS VERY LUCK TO HAVE BEEN ABLE TO STOP AND NOT HIT ANOTHER VEHICLE. *TR

NHTSA ID

10670701

Incident

Jan 2, 2015

Mileage

93,000 mi

BRAKE PEDAL WENT TO THE FLOOR UPON BRAKING. HAD TO DOWNSHIFT TO LOW GEAR AND APPLY WHAT LITTLE BRAKE I HAD LEFT TAKING APPROXIMATELY 200 FEET TO STOP. LUCKILY THERE WAS NO VEHICLE IN FRONT OF ME OR IT WOULD HAVE BEEN A REAR END COLLISION. SLOWLY RETURNED HOME ABOUT A MILE AWAY AND UPON FURTHER INSPECTION FOUND THE HARD BRAKE LINE RIGHT FRONT PASSENGER SIDE HAD BURST. NO PRIOR WARNING TO LOSS OF BRAKES. *TR

NHTSA ID

10660867

Incident

Nov 21, 2014

Mileage

67,880 mi

APPLIED BRAKES TO STOP AND PEDAL WENT TO FLOOR. UPON INSPECTION FOUND BRAKE LINE RUPTURED DUE TO EXCESSIVE CORROSION. VEHICLE REQUIRED 100% REPLACEMENT OF ALL BRAKE LINES. *TR

NHTSA ID

10654831

Incident

Oct 1, 2013

Mileage

95,000 mi

This Preliminary Information communication provides information to the technician about vehicles that may have an issue when using Bluetooth voice recognition with an iPhone. Technician should work with the customer to insure the phone contacts to not have any Emojis loaded to any contact.

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