2002 Chevrolet Silverado

On January 11, 2011, ODI opened EA11-001 to investigate allegations of premature brake line corrosion failure in model year (MY) 1999 through 2003 General Motors (GM) full-size pickup trucks and sport utility vehicles sold or registered in the following region of the United States that NHTSA has viewed as salt states for investigations of corrosion related issues: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 subject vehicles represent the first five MY's of GM's GMT800 platform production, of which approximately 2,038,504 vehicles were sold in salt states (the subject vehicles).The GMT800 platform includes the following vehicles:1999-2007 Chevrolet Silverado and GMC Sierra 1500, 2500 and 3500 series pick-up trucks; 2000-2006 Chevrolet Suburban, Chevrolet Tahoe and GMC Yukon sport utility vehicles; and 2002-2006 Cadillac Escalade and Chevrolet Avalanche sport-utility vehicles.General Motors produced a total of approximately 10,427,062 GMT800 vehicles for sales in the United States, including almost 5 million that were sold in salt states.Although there are over 60 different brake pipe routing configuration used in GMT800 vehicles, with the exception of the rear crossover pipes in MY 200x-2007 vehicles that changed from rear disc to drum brakes, all of the vehicles use brake pipes from the same supplier with a common double-wall, brazed steel pipe design with a combination of hot dip Zinc-Aluminum corrosion protection coating and Aluminum paint outer layer known in the industry as AlGal (ASTM-B750). ODI analysis of field data regarding GMT800 vehicles identified a total of 3,645 complaints of brake pipe corrosion failures, including 107 alleging crashes, and 40 injuries.Though only 20% of total GMT800 production, due to age and region the subject vehicles account for a disproportionate share of the failure experience; with 2,702 of the complaints (75%), 88 of the crashes (82%) and 20 of the injuries (50%) reported in those vehicles.Analysis of the complaints showed strong correlations to vehicle age and region.For vehicles with less than 8 years of service, the complaint rates were minimal for all regions.In the salt states the failure rates begin to climb as the vehicles advance in age, particularly in the Northeast corner of the United States.The complaint rates in the salt states go from less than 0.1 incident per thousand vehicles (IPTV) at 7 years in service to over 1.0 IPTV after the 12th year of service for the subject pickup trucks and utility vehicles.Most of the failures reported to ODI occurred in vehicles with more than 10 years in service.ODI?s investigation did not identify any specific defect conditions that were causing or contributing to the brake pipe failures.Nor did the analysis isolate the problem to any subject vehicle sub-populations when analyzed by vehicle type or production range.The investigation found that vehicles experiencing brake pipe corrosion failures were likely to have general patterns of excessive corrosion on the majority of the brake pipe assembly and appear to be occurring due to expected wear out for the brake pipe coating material used in the subject vehicles and the environmental conditions in severe corrosion states.A safety-related defect has not been identified at this time.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor t

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.

RUSTY BRAKELINES

NHTSA ID

10837591

Incident

Feb 22, 2016

Mileage

110,000 mi

TL* THE CONTACT OWNS A 2002 CHEVROLET SILVERADO. THE CONTACT HEARD AN ABNORMAL NOISE COMING FROM THE FRONT END OF THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE FRAME WAS RUSTED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 127,000.

NHTSA ID

10823108

Incident

Jan 13, 2016

Mileage

127,000 mi

WHILE DRIVING ON THE HIGHWAY, THE TRUCK, FOR AN UNKNOWN REASON, SHUT DOWN CAUSING ME TO LOOSE POWER STEERING AND BRAKE CAPABILITY. I WAS ABLE TO SHIFT INTO NEUTRAL AND TURN THE KEY OFF AND THEN BACK ON AGAIN TO RE-START THE TRUCK. IT HAS NOW HAPPENED SEVERAL TIMES AND I HAVE DONE THE SAME THING EACH TIME TO CORRECT THE PROBLEM. IT HAPPENED ONCE IN 2002 THEN CONSTANTLY 4-5 TIMES A YEAR AND AGAIN TODAY. GM HAS TOLD ME IN THE PAST THAT THEY DON'T KNOW WHAT WOULD CAUSE THAT ISSUE. I COULD NOT GET MY LOCAL CHEVROLET SHOP MANAGER TO GIVE ME A STRAIGHT YES OR NO ANSWER REGARDING WHETHER MY PROBLEM IS CONSISTENT WITH THE ISSUES BEING EXPERIENCED BY EFFECTED GM MODELS WITH IGNITION PROBLEMS. I BELIEVE IT MAY BE DUE TO THE RECALLED IGNITION SWITCHES AS I HAVE HAD THE ELECTRICAL SYSTEM LOOKED AT AND NO ONE CAN SEEM TO FIND AN ISSUE THAT WOULD CAUSE THE TRUCK TO SHUT OFF RANDOMLY AT HIGHWAY SPEEDS AND THEN TURN RIGHT BACK OVER AFTER SHIFTING TO NEUTRAL!! I BELIEVE THAT THE CURRENT RECALL DOES NOT COVER ALL OF THE VEHICLES THAT ARE TRULY AFFECTED. I HAVE HAD MY FAMILY IN THE TRUCK ON SEVERAL OCCASIONS WHEN THIS HAS HAPPENED AND HAVE BEEN FORTUNATE TO NOT HAVE HAD AN ACCIDENT TO THIS POINT.

NHTSA ID

10819155

Incident

Jan 9, 2016

Mileage

200,000 mi

ABOUT 165,000 MILES BRAKE PEDAL STARTED TO PULSATE AT LOW SPEED WHEN STOPPING.STARTED OUT ONLY WHEN I WOULD BE TURNING LEFT,NOW DOES IT GOING STAIGHT,ABOUT 170,000 MILES NOW.HAD NEW CALIPER ON DRIVER SIDE,NEW HUB ASSEMBLIE AND SENSOR ON PASSENGER SIDE,BRAKE SYSTEM FLUSHED,STILL HAVE PROBLEMS WITH BRAKE PEDAL PULSATING,DOES NOT MATTER WHAT KIND OF ROAD I'M ON.

NHTSA ID

10809877

Incident

Jul 6, 2015

Mileage

165,000 mi

TL* THE CONTACT OWNS A 2002 CHEVROLET SILVERADO. WHILE DRIVING AT A LOW SPEED, THE CONTACT APPLIED THE BRAKE PEDAL AND THE ABS KICKED IN; HOWEVER, THERE WAS A LOSS OF BRAKE FUNCTION. THE STOPPING DISTANCE OF THE VEHICLE WAS DRAMATICALLY REDUCED. THE VEHICLE WAS TAKEN TO A MECHANIC WHO STATED THAT THERE WAS A WHEEL BEARING SENSOR FAILURE. THE ENTIRE WHEEL BEARING WITH THE SENSOR WAS REPLACED, BUT THE FAILURE RECURRED MULTIPLE TIMES. THE CONTACT RESEARCHED AND FOUND NHTSA CAMPAIGN NUMBER: 05V379000. THE MANUFACTURER WAS NOTIFIED OF THE ISSUE. THE APPROXIMATE FAILURE MILEAGE WAS 90,000.

NHTSA ID

10776455

Incident

Sep 7, 2015

Mileage

90,000 mi

ABS STOPPED BRAKE PEDAL FROM GOING DOWN. BY THE TIME I LIFTED AND PUMPED AGAIN VEHICLE STRUCK YOUNG GIRL. TRAVEL WAS ABOUT SIX FEET. THERE IS A RECALL IN OTHER STATES BUT NOT KY.

NHTSA ID

10748950

Incident

Aug 12, 2015

Mileage

120,000 mi

WAS STARTING OUT OF DRIVEWAY ON SLIGHT SLOPE. APPLIED BRAKES AND ANTILOCK SYSTEM KICKED IN. UNDER 5MPH. ROLLED IN FRONT OF ONCOMING TRAFFIC. A TRUCK HAD TO VEER TO AVOID COLLISION WITH US. BECAME AWARE THERE IS A KNOWN PROBLEM BUT VEHICLE HADN'T BEEN RECALLED BECAUSE IT IS IN KENTUCKY. #05V379000 RECALL SHOULD BE EXTENDED TO KY BECAUSE OF SALT FOR SNOW AND GRAVEL ROADS.

NHTSA ID

10745478

Incident

Jul 30, 2015

Mileage

129,569 mi

TL* THE CONTACT OWNS A 2002 CHEVROLET SILVERADO. WHILE DRIVING 35 MPH, THE VEHICLE WOULD NOT STOP WHEN THE BRAKE PEDAL WAS DEPRESSED. THE CONTACT HAD TO USE THE EMERGENCY BRAKE TO FORCE THE VEHICLE TO STOP. THE DEALER DIAGNOSED THAT THE BRAKE LINES WERE LEAKING. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 99,610.

NHTSA ID

10723127

Incident

Jun 2, 2015

Mileage

99,610 mi

This technical bulletin provides a procedure to lube the rear leaf springs on vehicles with the condition of a squeak noise originating from the rear of the vehicle.

This Preliminary Information communication provides information to the technician about vehicles that may have slack in one of the tailgate cables. Technician should not replace any parts for this concern. Please communicate to the customer this condition is a normal operating characteristic of their vehicle.

This Preliminary Information communication advises the technician that the Hydro-Boost is not serviceable and will need to be replaced if the brake pedal moves or applies on its own at a full turn.

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

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.