2003 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.

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.

WHILE ROUTINELY DRIVING MY 03 CHEV SILVERADO TRUCK, THE BRAKES FAILED. WHEN I WAS ABLE TO SAFELY STOP AND MOVE TO A SAFE PLACE, I LOOKED UNDER THE VEHICLE AND SAW BRAKE FLUID LEAKING FROM ONE OF THE BRAKE LINES WHICH HAD FAILED DUE TO EXCESSIVE CORROSION. AS A RETIRED POLICE OFFICER, I HAVE EXCELLENT DRIVING SKILLS WHICH HELPED ME TO AVOID A COLLISION WITH ANOTHER VEHICLE WHEN THE BRAKES FAILED!

NHTSA ID

10852707

Incident

Mar 5, 2016

Mileage

210,515 mi

SIGNIFICANT CORROSION OF THE FUEL (GASOLINE) LINES CAUSING LEAK AND POSSIBLE SAFETY HAZARD (FIRE). SEVERAL FORUMS REPORT BRAKE AND FUEL LINE PREMATURE FAILURE DUE TO CORROSION. GM NOT ADDRESSING THIS KNOWN PROBLEM.

NHTSA ID

10838689

Incident

Feb 25, 2016

Mileage

124,000 mi

BRAKE LINES, GAS LINE, TRANSMISSION FLUID LINES ALL RUSTED/CORRODED BEGINNING AT UNDER 50,000 MILES. * HAD NEAR ACCIDENTS AS THE BRAKE LINES BLEW WHILE DRIVING ON A HIGHWAY AND WAS DECELERATING IN AN ATTEMPT TO COME TO A STOP..PEDAL WENT TO THE FLOOR, I CONTINUED ON (FOOT OFF THE GAS) UNTIL THE TRUCK SLOWED DOWN ENOUGH ON IT'S OWN, SHIFTED INTO LOW GEAR & WAS ABLE TO COME TO A STOP AND GET TOWED. * SHORTLY AFTER BRAKE LINE INCIDENT, THE SAME THING WITH THE GAS LINE, RUSTED/CORRODED AND LEAKED GASOLINE WHEN IGNITION WAS ON AND PUMP WAS RUNNING... TOWED * A FEW ,MONTHS LATER, I WAS PARKING THE TRUCK AND FLUID STARTED SPEWING FROM UNDER THE TRUCK - AFTER CLOSE EXAMINATION I DETERMINED IT WAS TRANSMISSION FLUID, THE LINES HAD RUSTED/CORRODED - AGAIN,TOWED. * REAR BUMPER ROTTED OUT COMPLETELY BEFORE HITTING 35,000 MILES- I HAD IT REPLACED, NOW THE WHEELS AND SIDE QUARTER PANELS AND EVERYTHING IN BETWEEN ARE ALSO ROTTING OUT. * CURRENTLY THE DASH LIGHTS/PANEL WILL INTERMITTENTLY BEGIN TO FLASH - THE WHOLE DASH GOES BLANK, LIGHTS OFF, THEN THEY COME BACK ON, WHILE DRIVING! **MY MECHANIC RECENTLY TOLD ME AFTER STATE INSPECTION, THAT THE FRAME IS THE NEXT THING TO GO, IT IS RUSTING OUT MORE THAN EXPECTED FOR A VEHICLE OF IT'S AGE/LOW MILEAGE. PERSONALLY, I FEEL THAT INFERIOR PRODUCTS WERE USED WHEN THE TRUCK WAS MANUFACTURED ONLY BECAUSE I HAVE ANOTHER CHEVROLET PRODUCT WITH TWICE THE MILEAGE AND 6 YEARS OLDER WITH BARELY ANY RUST/ROT/CORROSION.

NHTSA ID

10836694

Incident

Jan 1, 2013

FRONT BRAKE LINES RUSTED THROUGH AND SPILLED BRAKE FLUID WHILE MOVING AT SLOW SPEED. HAD FRONT BRAKE LINES REPLACED. SIX MONTHS OR SO LATER, REAR BRAKE LINES RUSTED THROUGH AND SPILLED BRAKE FLUID WHILE MOVING AT SLOW SPEED. HAD REAR BRAKE LINES REPLACED. ABS IS NOW CONTAMINATED AND IS CAUSING STOP TIME DELAY, ESPECIALLY AT HIGH SPEED. ALMOST CRASHED ON SEVERAL OCCASIONS WHERE MY HEART DROPPED TO MY STOMACH. DECIDED NOT TO DRIVE TRUCK ANYMORE UNTIL I CAN REPLACE THE ENTIRE BRAKE SYSTEM WITH RUST FREE COMPONENTS.

NHTSA ID

10823608

Incident

Jan 31, 2016

Mileage

129,000 mi

WHILE DRIVING, THE HEATER BLOWER STOPPED WORKING AND I SMELLED BURNING PLASTIC OR INSULATION. I PULLED OVER AND FIGURED OUT IT WAS COMING FROM UNDER THE DASH. LOGICALLY I PULLED THE BOTTOM COVER OFF FROM BELOW THE BLOWER ASSY.(FORMER MECHANIC). SMELL WAS COMING FROM PLUG HARNESS AND RELAY. MELTED WIRE INSULATION AND MELTED PLASTIC FROM PLUG HARNESS(OBVIOUS SHORT). I WAS NEAR AN AUTO PARTS STORE AND CHECKED TO SEE IF THEY HAD THIS WIRING PLUG ASSY. AND THEY INFORMED ME THAT THEY DID AND THIS WAS AN ISSUE THAT GM HAD AND THERE HAD BEEN A SAFETY RECALL ON THIS. IT'S WINTER AND I NEEDED A DEFROSTER! ROADSIDE FIX, BUT THIS COULD HAVE BEEN MUCH WORSE. CONTACTED GM AND THEY INFORMED ME THAT THIS WAS NOT THEIR PROBLEM BECAUSE THE VIN NUMBER WASN'T PART OF THEIR RECALL. GM CASE # 8-174060432. NOT DROPPING THIS, THIS COULD HAVE GOTTEN WORSE.

NHTSA ID

10817711

Incident

Jan 4, 2016

Mileage

126,000 mi

BRAKE LINE RUPTURE.

NHTSA ID

10806153

Incident

Nov 14, 2015

Mileage

191,830 mi

THE FRONT TO REAR BRAKES CORRODED TO THE POINT WHERE THEY BLEW OUT WHEN THE BRAKES WERE APPLIED WHILE DRIVING ON THE HIGHWAY.

NHTSA ID

10790172

Incident

Oct 30, 2015

Mileage

174,000 mi

ON OCTOBER 22,2015 WHILE DRIVEING ON INTERSTATE 75 THE FUEL PUMP STOPPED FUNCTIONING AND RESULTING IN A NEAR DISASTEROUS SITUATION.RESULTS $751.81 REPAIR COST PLUS TOW. THEN ONE WEEK LATER,OCTOBER 29 2015 AT WILMINGTON PIKE AND INERTSTATE 675 RED LIGHT MY BRAKE LINES BURST AND I NARROWLY AVOIDED A WRECK. REPAIR COST $870.17 .I WAS NOT NOTEAFIDE OF ANY RECALL. SO BE FAIR WARNING IF I HAD KNOWN OR BEEN I WOULD HAVE FIXED IT

NHTSA ID

10788515

Incident

Oct 22, 2015

Mileage

154,457 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.