2003 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.

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.

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.

GENERAL MOTORS FILED A DEFECT NOTICE 04V-129 ON MARCH 17, 2004, WHICH OUTLINES A PROGRAM TO REPLACE THE TAILGATE CABLES INSTALLED IN AFFECTED MODEL YEAR 2000-2004 VEHICLES.REFER TO ODI'S CLOSING REPORT FOR EA04-005 FOR ADDITIONAL INFORMATION.ODI IS AWARE OF REPORTS OF TAILGATE CABLE BREAKAGE OCCURRING IN MODEL YEAR 1999 AND EARLIER VEHICLES.THESE VEHICLES WERE EQUIPPED WITH SIMILAR TAILGATE CABLES AS ADDRESSED BY 04V-129, BUT ARE NOT BEING ADDRESSED BY CAMPAIGN O4V-129.ODI IS INITIATING A SEPARATE INVESTIGATION TO ADDRESS THESE VEHICLES.THE COMPLAINT-INJURY-FATALITY STATISTICS SUMMARIZED ABOVE PERTAIN TO MODEL YEAR 2000-2004 VEHICLES. THE COMPLAINT-INJURY STATISTICS FOR MODEL YEAR 1999 AND EARLIER VEHICLES ARE SUMMARIZED ON THE OPENING RESUME FOR THAT INVESTIGATION.

MY 17 YEAR OLD SON WAS ON THE FREEWAY AND THE BRAKE PEDAL TRAVELLED ALL THE WAY TO THE FLOOR WHILE ATTEMPTING TO STOP. THE SERVICE BRAKE SYSTEM LIGHT CAME ON AT THE SAME TIME. STOPPING DISTANCE WAS INCREASED DRAMATICALLY, BY AT LEAST DOUBLE. IF THERE WOULD HAVE BEEN A CURVE OR CAR IN FRONT OF HIM THERE WOULD HAVE BEEN AN ACCIDENT. PARKED THE TRUCK UNTIL IT COULD BE INSPECTED AND FOUND A LEAK UNDER DRIVER SIDE FRONT DOOR. ALL OF THE MAIN BRAKE PIPES WERE RUSTED AND FRAGILE. TAKING TRUCK TO DEALERSHIP TO HAVE ALL BRAKE PIPES REPLACED WITH KIT MENTIONED IN (TSB) 13-05-22-001. I AM VERY DISAPPOINTED THAT GM IS FIGHTING A RECALL BY SIGHTING THE FACT THAT THERE ARE TWO DIFFERENT BRAKE SYSTEMS AND IT IS NOT A SAFETY ISSUE. WHAT IF THE RUSTED BRAKE LINES FOR BOTH SYSTEMS FAILED. AT THE VERY LEAST IT SEEMS THAT HAVING YOUR STOPPING DISTANCE INCREASE BY ALMOST DOUBLE WITH OUT WARNING IS A SAFETY ISSUE.

NHTSA ID

10855523

Incident

Mar 26, 2016

Mileage

170,000 mi

TL* THE CONTACT OWNS A 2003 CHEVROLET AVALANCHE. WHILE DRIVING APPROXIMATELY 65 MPH, THE INSTRUMENT PANEL FAILED. IN ADDITION, THE DRIVER SIDE HEADLIGHT FAILED. THE FAILURE RECURRED NUMEROUS TIMES. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE INSTRUMENT PANEL NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN WAS UNKNOWN. THE APPROXIMATE FAILURE MILEAGE WAS 70,000.

NHTSA ID

10837117

Incident

Jul 12, 2010

Mileage

70,000 mi

BRAKE LINE FAILURE: I HAD A RUPTURED STEEL BREAK LINE FAILURE WHILE APPLYING NORMAL BREAKING PRESSURE ON THE PEDAL. AFTER FURTHER INSPECTION OF BREAK LINES, I FOUND ALL BREAK LINES WERE RUSTED AND IN DANGER OF ALSO RUPTURE.

NHTSA ID

10747108

Incident

Jul 29, 2015

Mileage

179,000 mi

THE OTHER DAY I STARTED NOTICING THAT WHEN I TURN RIGHT (OR LEFT IN REVERSE) AT A LOW RATE OF SPEED THE VEHICLE MAKES A CLUNKING NOISE AND MY STEERING IS AFFECTED. I STARTED LOOKING ONLINE FOR A REMEDY TO THIS PROBLEM AND FOUND THAT SEVERAL PEOPLE HAD THE SAME PROBLEM AND DID NOT KNOW WHERE TO REPORT IT. I DON'T FEEL IT IS FAIR THAT AS THE CONSUMER THAT I AM RESPONSIBLE FOR A DESIGN FLAW BY GM. I ALSO DON'T FEEL ITS FAIR TO HAVE TO SPEND UP $400 WHEN ITS ALL SAID AND DONE EACH TIME THAT IT WILL HAVE TO BE REPAIRED.

NHTSA ID

10725848

Incident

Jun 13, 2015

Mileage

181,062 mi

TL* THE CONTACT OWNS A 2003 CHEVROLET AVALANCHE. WHILE DRIVING AT AN UNKNOWN SPEED, THE BRAKE PEDAL EXTENDED TO THE FLOOR WHEN IT WAS DEPRESSED. THE CONTACT DISCOVERED THAT THE BRAKE LINES NEAR THE DRIVER SIDE DOOR WERE RUSTED AND CORRODED, AND BRAKE FLUID HAD LEAKED FROM THE VEHICLE. THE CONTACT INDICATED THAT THE BRAKE LINES HAD BEEN PREVIOUSLY REPLACED ON THE VEHICLE DUE TO RUSTING AND CORROSION. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 150,000.

NHTSA ID

10723547

Incident

Jun 3, 2013

Mileage

150,000 mi

TL* THE CONTACT OWNS A 2003 CHEVROLET AVALANCHE.WHILE AT A TRAFFIC LIGHT, THE CONTACT COULD NOT DEPRESS THE BRAKE PEDAL. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN WAS NOT AVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 115,000.

NHTSA ID

10701341

Incident

Mar 23, 2015

Mileage

115,000 mi

VEHICLE EXPERIENCED COMPLETE BRAKE FAILURE UPON SLOWING FOR A TRAFFIC LIGHT. THIS WAS COMPOUNDED BY THE DOWNHILL ORIENTATION OF THE ROAD SURFACE. LEFT ROADWAY TO AVOID COLLISION WITH TRACTOR-TRAILER. THERE WAS NO WARNING OR INDICATION OF AN IMPENDING BRAKE FAILURE. NO INDICATION THAT ANY PART OF THE BRAKING SYSTEM WAS STILL FUNCTIONING. IT WAS DISCOVERED UPON INSPECTION THAT THE BRAKE LINES WERE EXCESSIVELY CORRODED COMPARED WITH OTHER BODY AND ENGINE COMPONENTS. METAL COMPOSITION OF BRAKE TUBING SEEMS VERY PRONE TO CORROSION. COMPLETE BRAKE LINE REPLACEMENT OF THE ENTIRE SYSTEM IS NOW NECESSARY. *TR

NHTSA ID

10691263

Incident

Jan 9, 2015

Mileage

110,000 mi

THE REAR BRAKE LINE BURST CATASTROPHICALLY AND MY BRAKE PEDAL WENT TO THE FLOOR. I WAS COMING UP TO STOPPED CARS AT AN INTERSECTION AND HAD TO SWERVE INTO THE ONCOMING LANE TO AVOID REAR ENDING ANOTHER TRUCK. LUCKILY THERE WERE NO CARS IN THE LANE AT THE TIME. I THEN HAD TO MAKE A SHARP TURN INTO A SHOPPING CENTER PARKING LOT TO AVOID RUNNING THROUGH THE INTERSECTION (WHICH DID HAVE TRAFFIC). I HAD ZERO BRAKING POWER WHATSOEVER. I TRIED PUSHING DOWN THE EMERGENCY BRAKE AND IT HAD NO EFFECT ( I LATER FOUND THAT THE EMERGENCY BRAKE LINES WERE FROZEN IN A LARGE CHUNK OF ICE NEAR THE DRIVERS SIDE REAR WHEEL AND WOULD NOT MOVE). THE PICKUP BED DRAINS DOWN ONTO THE LOWER FRAME IN THIS AREA AND THAT ACCOUNTED FOR THE ICE BUILDUP. I CONTINUED THROUGH THE SHOPPING CENTER PARKING LOT AND ALL I COULD TO WAS DOWNSHIFT TO SLOW MYSELF DOWN. LUCKY AGAIN...THE PARKING LOT WAS NEARLY EMPTY AND VERY LONG. AFTER ABOUT 4-500 FT I WAS GOING SLOW ENOUGH THAT I WAS ABLE TO JAM THE TRANSMISSION INTO PARK. THERE WAS NO WARNING OF THIS FAILURE. THE LINES WERE NOT LEAKING. I HAVE NOW READ ONLINE THAT GM HAS HAD MANY COMPLAINTS OF RUSTED LINES ON THEIR PICKUPS SUDDENLY FAILING. THIS COULD HAVE BEEN A LIFE THREATENING SITUATION. BRAKE LINES SHOULD NOT SUDDENLY FAIL. THEY SHOULD LAST THE LIFE OF THE VEHICLE. NON-CORROSIVE NICKLE COPPER BRAKE LINES EXIST THAT DO NOT RUST. THESE SHOULD BE MANDATORY ON ALL VEHICLES. *JS

NHTSA ID

10690668

Incident

Feb 24, 2015

Mileage

96,522 mi

This Preliminary Information communication advises the technician that if OnStar is unable to configure the vehicle after the OnStar 15-08-44-001 upgrade and Onstar receives a 118 error code when attempting to configure the vehicle. Dealers should receive a sheet with the kit that provides steps to assist with handling this error. Dealer will follow one of the listed steps to resolve the issue. If there are still configuration issues, please contact the OnStar Technical Assistance Centre for assistance.

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.

THIS PRELIMINARY INFORMATION COMMUNICATION PROVIDES INFORMATION TO THE TECHNICIAN ABOUT FINDING NEEDLE BEARINGS DURING AN OIL CHANGE. TECHNICIAN WILL GAIN ACCESS TO THE ROLLER ROCKERS TO INSPECT THEM. ONLY REPLACE THE ROLLER ROCKER THAT IS MISSING NEEDLE BEARINGS. BE SURE TO CLEAN THE OIL DRAINS TO RETRIEVE THE NEEDLE BEARINGS. EACH ROLLER ROCKER HAS 66 BEARINGS.

This informational bulletin provides information on Part Restriction and Ordering Process Information for OnStar Vehicle Communication Interface Modules (VCIM) (GMNA Only)

This Preliminary Information communication provides information to the technician about gasoline powered cars, mid-size trucks, light duty trucks, and heavy duty trucks with premature catalytic converter failures. It is recommended to inspect for a poor crimp on the grounds ring terminal at the engine block for the bank with the concern and repair the wire.

This informational bulletin provides information to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking.