2004 Chevrolet Silverado 2500 Brakes Problems

Hydraboost piston blew out, lost brakes and steering. Almost wrecked vehicle.

NHTSA ID

11561107

Incident

Dec 18, 2023

I HAVE CHANGED ALL 4 NEW TIRES IN 4 DIFFERENT TIMES EVERY YRS NOT SURE IF THAT A WHEEL PROBLEM. AND ALSO FIX MY FUEL INJECTION SYSTEM THAT WAS GIVE ME A PROBLEM IN THE PAST. NOW I REPLACE ALL NEW ROTOR BRAKE DISCS AND PAD IN 30 MINUTES OUT FROM A MECHANICAL SHOP IT'S SHOW A ENGINE LIGHT NOW SAYING RANGE SHIFT INHIBITED ON MY DASHBOARD. AND WHEN I'M SHIFTING TO DRIVE IT JUST REVERSE INSTEAD OF DRIVE. NOW IS BACK IN THE SHOP FOR NOW PROBLEM TO COME. FROM GARDEN CITY KANSAS

NHTSA ID

11289545

Incident

Dec 16, 2019

Mileage

315,000 mi

BRAKE LINES FAILED AFTER HAVING ALREADY BEEN REPLACED. FACTORY LINES CORRODED THROUGH AND TRUCK WAS SCARY TO SLOW DOWN. WAS FORTUNATE TO BE GOING AT LOW SPEEDS IN A RESIDENTIAL AREA - BUT GLAD THERE WERE NO KIDS AROUND AND I NEEDED TO BRAKE QUICKLY!

NHTSA ID

11218655

Incident

Jun 8, 2019

Mileage

55,000 mi

I HAVE HAD A COMPLETE BRAKE JOB BECAUSE ALL OF THE LINES RUSTED OUT AND FAILED AS I WAS DRIVING. FORTUNATELY, I WAS ABLE TO USE THE EMERGENCY BRAKE TO STOP SAFELY. I SPENT ROUGH.Y $3,000 TO GET THIS REPAIRED. NOW THE FUEL LINES, FUEL COOLER AND EVERYTHING ATTACHED HAS RUSTED OUT TO THE POINT THAT IT IS GOING TO BE AN ADDITIONA $2,500 TO REPAIR THIS. ALSO, THE COMPLETE UNDER CARRIAGE AND REAR END HAS RUSTED TO THE POINT THAT I AM EXPECTING IT TO FAIL AT ANY TIME. THIS IS NOT ONLY A DANGEROUS SITUATION, BUT IS EXTREMELY COSTLY TO THE CONSUMER, ME. WHEN THE BRAKES FAILED, I WAS DRIVING ON A STREET APPROACHING A BUSY INTERSECTION. WITH NO WARNING AT ALL, THE PEDAL WENT TO THE FLOOR AND I HAD NO BRAKES. THE REPAIR FACILITY MECHANIC SAID HE HAS NEVER SEEN A SYSTEM SO BAD. I KEEP THE VEHICLE IN A GARAGE AND HAVE WASHED THE UNDER CARRIAGE IN THE WINTER TO KEEP ROAD SALT FROM ACCUMULATING.

NHTSA ID

11102632

Incident

Mar 15, 2016

Mileage

42,000 mi

TOTAL BRAKE FAILURE WHEN ATTEMPTING TO SLOW/STOP VEHICLE TO MAKE A TURN. DROVE INTO PARKING LOT TO GET OFF OF ROADWAY, HIT SIGN, TREE, PARKED VEHICLE BEFORE VEHICLE FINALLY STOPPED.

NHTSA ID

11023738

Incident

Aug 29, 2017

Mileage

75,000 mi

ENGINE RUNS ROUGH AT IDLE.CK ENGINE LIGHT ON.

NHTSA ID

10954870

Incident

Aug 22, 2016

Mileage

139,000 mi

BRAKE LINES HAVE STARTED RUSTING OUT. ONLY 120K ON THE TRUCK. CALLED GM. GM WILL NOT HELP WITH THIS KNOWN ISSUE OF THE BRAKE LINES CORRODING. HAD 1LINE FIXED AFTER IT BLEW COMING TO A STOP BY MY HOUSE. SECOND LINE BLEW YESTERDAY SLOWING DOWN WHILE EXITING THE FREEWAY

NHTSA ID

10948712

Incident

Jan 30, 2017

Mileage

120,000 mi

BRAKE LINES AND RELATED CALIPERS CONTINUE TO RUST AND FAIL. HAVE NOW LOST BRAKES WHILE DRIVING DUE TO FAILURE OF VARIOUS BRAKE LINES THREE TIMES. TWICE I LOST THE BRAKES WHILE DRIVING IN HIGHWAY TRAFFIC. ONCE WHILE BACKING SLOWLY DOWN A RAMP TO A DOCK. HAVE HAD LINES REPLACED 3 TIMES NOW. CALIPERS ALSO REPLACE. VEHICLE IN SHOP FOR EMERGENCY REPAIR NOW. PREVIOUS DEALERS HAVE SAID THIS PROBLEM IS RELATED TO THE NEW BRINE MATERIAL APPLIED TO ROADS BY DOT IN WINTER. NOTE THAT I DO CLEAN UNDERCARRIAGE TO REMOVE SALT. ALSO HAVE HAD SEVERAL OLDER VEHICLES OTHER MAKES/ MODELS DURING SAME TIME PERIOD AND HAVE NOT HAD THIS ISSUE. NEVER REPLACE BRAKE LINES ON OTHER VEHICLES. *TR

NHTSA ID

10917508

Incident

Oct 20, 2016

Mileage

107,000 mi

WHILE TRAVELING 50 MPH TOWING A BOAT APPLIED THE BRAKES , THE VEHICLE SLOWED DOWN AND THE BRAKE PEDAL WENT TO THE FLOOR WITH THE UNITS FINALLY STOPPING . ALL BRAKE FAILURE WARNING LIGHTS LIGHT UP ON THE DASH AND UPON INSPECTION IT WAS DISCOVERED THE BRAKE LINE TO THE RIGHT FRONT WHEEL HAD RUSTED THROUGH AND BLEW OUT ALL THE BRAKE FLUID DIRECTLY UNDER THE DRIVERS DOOR. ALL REMAINING BRAKE LINES ARE SEVERELY RUSTED AND APPEAR SWOLLEN AS TO BE READY TO BURST AS WELL UNDER THE DRIVERS DOOR ALONG THE FRAME RAIL. VEHICLE HAS 2,760 ENGINE RUNNING HOURS ON IT WITH 82,500 MILES DRIVEN. ALL BRAKE LINES ARE ORIGINAL TO THE TRUCK .DEALER ESTIMATE TO REPLACE ALL BRAKE LINES WAS IN EXCESS OF $2,000. THIS VEHICLE IS ONLY DRIVEN ON THE HIGHWAY AND NEVER OFF ROAD. I HAVE OWNED MANY VEHICLES OVER THE YEARS AND THIS VEHICLE IS THE ONLY ONE THAT HAS SUFFERED A CATASTROPHIC BRAKE FAILURE WHICH THANKFULLY DID NOT END IN A CRASH. AFTER FURTHER INVESTIGATION WITH OTHER SIMILAR TRUCK OWNERS I HAVE DISCOVERED THIS HAS BEEN A COMMON PROBLEM THAT IN NOW SURFACING AND MAY RESULT WITH TRAGIC CONSEQUENCES IF NOT ADDRESSED BY NHTSA AND GM IMMEDIATELY.

NHTSA ID

10895736

Incident

Aug 7, 2016

Mileage

82,500 mi

ON 4/28/2016 TRAVELING TO WORK FOLLOWING A TRACTOR TRAILER IN A 55 MPH ZONE, THE TRACTOR TRAILER ABRUPTLY MERGED INTO THE RIGHT TURN LANE AFTER A CURVE WITHOUT A SIGNAL LEAVING TWO STOPPED CARS IN MY TRAVEL LANE MAKING A LEFT TURN. I APPLIED HARD PRESSURE TO MY BRAKES AND THE PEDAL WENT TO THE FLOOR. I IMPACTED AN AVALANCHE THAT WAS PUSHED INTO A SMALL COMPACT CAR CAUSING SUBSTANTIAL DAMAGE TO MY VEHICLE AND THE AVALANCHE. THE DRIVER OF THE AVALANCHE WAS TRANSPORTED TO THE HOSPITAL WITH MINOR INJURIES. WHILE AT THE ACCIDENT SCENE I NOTICED FLUID LEAKING UNDER MY TRUCK JUST BEHIND THE LEFT REAR TIRE. THE TRUCK WAS TOWED FROM THE SCENE TO A BODY SHOP WHERE THEY DISCOVERED 2 RUPTURED BRAKE LINES IN BETWEEN THE MASTER CYLINDER AND PROPORTIONING VALVE. ATTACHED PICTURES SHOW SEVERALLY RUSTED BRAKE LINES WITH NO OTHER RUST OR CORROSION ON PARTS IN THE SURROUNDING AREA. INITIAL ESTIMATE FOR REPAIRS ON MY TRUCK WERE $6,371 BEFORE TEAR DOWN.

NHTSA ID

10870153

Incident

Apr 28, 2016

Mileage

105,000 mi

GOING DOWN EXIT RAMP BRAKE PEDAL WENT TO FLOOR. HAD I NOT MANAGED TO GET VEHICLE STOPPED WITH AGGRESSIVELY PUMPING BRAKE PEDAL WHILE READY ON PARKING BRAKE WE WOULD HAVE GONE INTO THREE LANES OF CROSS TRAFFIC GOT VEHICLE HOME AND FOUND EXTREMELY CORRODED BRAKE LINES UNDERNEATH DRIVER SIDE WITH ONE LEAKING OVER THE YEARS I'VE WORKED AROUND EQUIPMENT AND NEVER SEEN ANYTHING THIS BAD ON A PASSENGER VEHICLE OF ANY KIND. WE LIVE IN THE SOUTH AND THIS VEHICLE IS NOT AFFECTED BY EXTREME WINTER CONDITIONS. THE VEHICLE HAS BEEN WELL MAINTAINED AND I CONSIDER THIS A SERIOUS SAFETY CONCERN.

NHTSA ID

10861311

Incident

Apr 23, 2016

Mileage

103,139 mi

TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500 HD. WHILE DRIVING 45 MPH, THE BRAKE PEDAL WAS DEPRESSED BUT THE VEHICLE HESITATED TO RESPOND WITHOUT WARNING. THE VEHICLE EVENTUALLY STOPPED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 137,000. THE VIN WAS NOT AVAILABLE. UPDATED 05/31/2016*LJ THE CONSUMER STATED AS HE APPROACHED A STOP SIGN, HE PRESSED THE BRAKE PEDAL AND IT WENT TO THE FLOOR. HE PUMPED THE BRAKE AND EVENTUALLY STOPPED THE VEHICLE SAFELY. IT WAS DETERMINED, THE BRAKE LINE HAD RUSTED THROUGH. UPDATED 06/09/16.*JB

NHTSA ID

10860239

Incident

Apr 19, 2016

Mileage

137,000 mi

ON MY WAY HOME FROM WORK THE RUSTED BRAKE LINES ON MY TRUCK FAILED. SADLY, GM HAS KNOWN FOR YEARS THAT THESE LINES WERE MADE POORLY AND THAT THIS HAS BEEN AN ISSUE. YET THEY HAVE FAILED TO NOTIFY CONSUMERS OR VOLUNTARILY REPLACE THESE PARTS WITH SOME OF HIGHER QUALITY. UNFORTUNATELY, THE NHTSA ISN'T ANY BETTER, AS THEY HAVE BEEN "INVESTIGATING" THIS ISSUE FOR A NUMBER OF YEARS BUT HAVE YET TO FORCE THE AUTO MAKER TO CORRECT THIS PROBLEM. CLEARLY NOT ENOUGH PEOPLE HAVE DIED FROM THIS ISSUE TO MERIT THEM WORKING IN THE PUBLICS BEST INTEREST AND NOT BE IN THE AUTO MAKERS BACK POCKET.

NHTSA ID

10860212

Incident

Apr 18, 2016

Mileage

107,000 mi

REPLACED ALL BRAKE LINES RUSTED THROUGH 107,000 MILES ON A 2004 TRUCK. ALUMINUM WHEELS ARE PITTED APPEARS TO BE LOSING THE COATIING THE PASSENGER SIDE DOOR IS SHOWING RUST. HEADLINER IS FALLING DOWN IN THE FRONT OF THE VEHICLE. THE REAR RADIO SPEAKERS ARE NOT WORKING

NHTSA ID

10823323

Incident

Jan 28, 2016

Mileage

107,000 mi

BRAKE PEDAL WENT TO THE FLOOR TRYING TO AVOID HITTING ANOTHER CAR TRAVELING AT 60 MPH ON THE INTERSTATE , STEEL BRAKE LINE UNDER DRIVERS DOOR RUSTED AND BROKE .

NHTSA ID

10818523

Incident

Jan 4, 2016

Mileage

293,000 mi

DURING A HIGHWAY BRAKING EVENT, BRAKE LINES BLEW OUT DUE TO RUSTING, CAUSING COMPLETE BRAKE FAILURE.

NHTSA ID

10788750

Incident

Jul 8, 2015

Mileage

190,000 mi

BRAKES FAILED UNDER HARD STOP (HIGHWAY, IN MOTION) TO AVOID A COLLISION WITH DEER. MASTER CYLINDER TO ABS MODULE STEEL BRAKE LINE FAILED IN A MODE OF RUPTURE DUE TO CORROSION. ALL OTHER STEEL LINES WERE CORRODED AND CONTACTED GM. 2 OTHER SILVERADO LINE VEHICLES OWNED ALSO FAILED THIS YEAR DUE TO CORROSION. GM RESPONSE WAS THAT NO RECALL EXISTED. REPLACED ALL STEEL BRAKE LINES IN VEHICLE WITH STAINLESS AFTERMARKET LINES. AFTER MULTIPLE CONTACTS WITH GM CUSTOMER SERVICE, I WAS TOLD TO SAVE MY RECEIPTS FOR REPAIRS. THIS IS AN INCORRECT MATERIAL SPECIFICATION, LATENT DEFECT AND GM NEEDS TO BE HELD ACCOUNTABLE. 3 VEHICLES THAT I OWN WITH THE SAME REPAIR IN 8 MONTHS. INEXCUSABLE!

NHTSA ID

10786250

Incident

Mar 11, 2015

Mileage

164,000 mi

REAR BRAKE LINE FAILURE DUE TO CORROSION. FAILURE POINT BETWEEN GAS TANK AND REAR FRAME RAIL WHERE HYDRAULIC LINE IS MOUNTED ON LH SIDE OF VEHICLE. UPON APPLYING BRAKES, THE LINE BLEW CAUSING NEAR TOTAL BRAKE FAILURE COMING TO STOP LIGHT NARROWLY AVOIDING THE CAR IN FRONT OF ME. THERE WAS JUST ENOUGH PRESSURE FOR FRONT BRAKES TO GRAB BARELY STOPPING THE VEHICLE. THERE IS NO REASON FOR THIS TO HAPPEN CONSIDERING THE COATING TECHNOLOGY AVAILABLE IN 2004. THIS TRUCK IS RATED @ 9200 GVW WITH A TOWING CAPACITY OF 10,000 POUNDS. IF THIS TRUCK WAS FULLY LOADED THE RESULTS COULD HAVE BEEN CATASTROPHIC IN THE RIGHT SITUATION.

NHTSA ID

10762035

Incident

Sep 7, 2015

Mileage

250,000 mi

AS TRAFFIC SLOWED AHEAD OF ME I APPLIED MY BRAKES AND THE PEDAL WENT TO THE FLOOR. I THEN USED MY PARKING BRAKE TO STOP. I STOPPED AN INCH AWAY FROM THE CAR AHEAD OF ME. VEHICLE WAS TOWED TO REPAIR SHOP. UPON INSPECTION THE TECHNICIAN SAID THE BRAKE LINE FAILED AND THE OTHER BRAKE LINES WERE ALSO RUSTED BAD AND NEEDED TO BE REPLACED. HE ALSO SAID THE FUEL LINES WERE RUSTED AND SHOULD BE REPLACED SOON. I WAS VERY LUCKY I WAS ABLE TO STOP IN TIME . I COULD HAVE INJURED OTHER PEOPLE IN FRONT OF ME.

NHTSA ID

10745994

Incident

Jul 25, 2015

Mileage

81,238 mi

I WAS TOWING MY RV. WHEN I HIT THE BRAKES AND THE BRAKE PEDAL WENT TO THE FLOOR. SCARED THE BLANK OUT OF ME SINCE I HAD MY WIFE AND TWO KIDS WITH ME. THE BRAKE LINE FOR THE REAR BRAKES BLEW DUE TO CORROSION. THE ONLY THING THAT SAVED US WAS THE TRAILER BRAKES OR WE WOULD HAVE HAD A SERIOUS ACCIDENT. GM IS SO CHEAP THEY BUILD THEIR BRAKE SYSTEM WITH LINES THAT EASILY CORRODE IN STEAD OF STAINLESS. THERE SHOULD BE A RECALL. THE INTERNET IS LITTERED WITH THIS ISSUE. THERE SHOULD BE A REGULATION FORCING MANUFACTERS TO USE CORROSION PROOF BRAKE LINES. RIDICULOUS!!!

NHTSA ID

10736175

Incident

Jul 23, 2015

Mileage

159,037 mi

FIRST TIME BRAKE LINE FAILED MY WIFE WAS AT A FAST FOOD DRIVE THRU AND WHEN LEAVING WINDOW APPLIED BRAKES AND PEDAL WENT TO THE FLOOR. TWO BRAKE LINES HAD TO BE REPLACED GOING TO ABS MODULE/MOTOR PACK. THE NEXT TIME WAS ABOUT A YEAR LATER,HAD MOVED THE TRUCK FROM BOTTOM OF DRIVEWAY TO TOP AND PARKED IT. A COUPLE OF HOURS LATER BRAKE LINE BROKE UNDER DRIVERS SEAT. EACH TIME HAD TO HOLD PEDAL DOWN FOR 5-10 SECONDS TO FIND LEAKING FLUID. THE FLUID WAS APPARENTLY SPRAYING ON THE FRAME AND RUNNING DOWN IT. THE THIRD TIME ANOTHER LINE BUSTED. STOPPED PERFECT AT STOP SIGN IN NEIGHBORHOOD AND WHEN REACHING THE SECOND PEDAL WENT TO THE FLOOR. NO WARNING AT ALL THREE EVENTS. BRAKE PEDAL WENT FROM NORMAL TO GOING TO THE FLOOR. THERE WAS NO SOFTNESS OR EXTRA TRAVEL PRIOR TO ALL THREE TIMES. THE TRUCK NOW HAS 85,000 MILES ON IT. MY LOCAL DEALERS ANSWER TO WHY THIS KEEPS HAPPENING WAS IT IS 11 YEARS OLD, MAYBE YOU SHOULD TALK TO SALES ABOUT GETTING A NEW ONE. I LOVE THIS TRUCK MINUS THE BRAKE ISSUES

NHTSA ID

10717755

Incident

Apr 18, 2013

TL* THE CONTACT OWNS A 2004 CHEVROLET SILVERADO 2500 HD. WHILE DRIVING APPROXIMATELY 10 MPH, A HUMMING SOUND EMITTED FROM THE ACCELERATOR PEDAL THAT BECAME LOUDER WHEN THE VEHICLE ACCELERATED. ALSO, THE CONTACT STATED THAT THE BRAKE PEDAL WAS DIFFICULT TO DEPRESS WITHOUT WARNING. THE FAILURE RECURRED NUMEROUS TIMES. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHERE IT WAS DIAGNOSED THAT THE BRAKE HYDRO BOOSTER NEEDED TO BE REPLACED OR REBUILT. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND STATED THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 05V043000 (SERVICE BRAKES, HYDRAULIC). THE APPROXIMATE FAILURE MILEAGE WAS 216,000.

NHTSA ID

10703402

Incident

Mar 30, 2015

Mileage

216,000 mi

BRAKE LINE BLEW AND BRAKES WENT TO THE FLOOR. *TR

NHTSA ID

10700831

Incident

Mar 20, 2015

Mileage

131,321 mi

I WAS TRAVELING HOME FROM DROPPING MY DOG OFF AT HIS GROOMER. I WENT TO BRAKE COMING TO AN INTERSECTION TO PREPARE FOR A CHANGE IN THE LIGHT WHEN THE BRAKE PEDAL WENT STRAIGHT DOWN TO THE FLOOR WITH NO WARNING LIGHT IN THE GAUGES OR INFORMATION SYSTEM UNTIL AFTER THE INCIDENT HAPPENED. I HAD VERY LITTLE BRAKING AT ALL AND WAS ABLE TO GET THE TRUCK TO MY RESIDENT WITHOUT INCIDENT. I HAD THE TRUCK TOWED TO A MECHANIC WHO INFORMED ME THE BRAKE LINE HAD RUSTED COMPLETELY THROUGH. I HAVE READ MANY COMPLAINTS BEING FILED BY OTHER CHEVY SILVERADO OWNERS. WHEN IS GM GOING TO BE HELD RESPONSIBLE FOR FAILING PARTS ON ALL OF THEIR VEHICLES? I WAS A LUCKY INDIVIDUAL THAT IT WAS EARLY MORNING AND VERY LITE TRAFFIC ON THE ROAD I WAS TRAVELING. *TR

NHTSA ID

10694505

Incident

Mar 14, 2015

Mileage

130,000 mi

MY 2004 CHEVROLET SILVERADO 2500 HD HAS HAD MULTIPLE BRAKE ISSUES. THE BRAKE LINES AND FUEL LINE HAVE RUSTED OUT. APPROXIMATELY 2 YEARS AGO I HAD BREAK LINE RUST OUT AND THEY WHERE REPLACED. THEY HAVE RUSTED OUT AGAIN.MY TRUCK IS VERY WELL CARED FOR AND IS CLEAN AND NOT DRIVEN OFTEN. I HAVE HAD MULTIPLY CONVERSATIONS WITH GENERAL MOTORS HOTLINE AND HAVE NOT GOT ANYWHERE. I HAVE RESEARCHED THE WEB AND SEE THIS IS A BIG PROBLEM WITH GENERAL MOTORS PRODUCTS.MY TRUCK NOW HAS ABOUT 70,000 MILES AND IS STILL VERY CLEAN AND VERY WELL KEPT. I HOPING SOME ONE COULD LOOK OUT FOR THE CONSUMER AND REQUEST THEY HAVE A RECALL OF THERE PRODUCT BEFORE SOME ONE IS INJURED OR KILLED. *TR

NHTSA ID

10679639

Incident

Jan 23, 2013

Mileage

56,000 mi