2004 Chevrolet Suburban 2500

BRAKE LINES BETWEEN THE AREA OF THE BRAKE FLUID RESERVOIR AND ABS MODULATOR HEAVILY CORRODED. ONE OR MORE LINES FAILED ON 7/10/2016 REQUIRING VEHICLE TOW. VEHICLE WAS OPERATIONAL ASIDE FROM THE FAILURE OF BRAKING SYSTEM. WHEN DEPRESSED, VEHICLE BRAKE PEDDLE HAD LITTLE RESISTANCE AND TRAVELED COMPLETELY TO FLOOR PANEL UNDER NORMAL PRESSURE FROM FOOT. THE INCIDENT/FAILURE OCCURRED DURING NORMAL TRAVEL AND DURING AN ATTEMPTED STOP AT RED LIGHT. BRAKE SYSTEM FAILURE PREVENTED A SAFE STOP AND THE VEHICLE CONTINUED THROUGH THE INTERSECTION RUNNING A RED LIGHT. FORTUNATELY, THE INTERSECTION WAS CLEAR AND NO ACCIDENT OCCURRED. THE VEHICLE WAS PARKED IMMEDIATELY AFTERWARDS AND A TOW VEHICLE CALLED. THE VEHICLE IS CURRENTLY PARKED UNTIL REPAIRS CAN BE APPLIED. TOWING EXPENSE- 125.00 PARTS EXPENSE- 85.00 (REPLACING ALL AFFECTED LINES, FRONT BRAKING SYSTEM.) LABOR- 100.00 APPROX.

NHTSA ID

10883886

Incident

Jul 10, 2016

Mileage

103,500 mi

FUEL RUNNING OUT TOP OF GAS TANK AFTER FUELING

NHTSA ID

10865319

Incident

May 15, 2016

Mileage

144,000 mi

WHILE VEHICLE WAS STATIONARY AT IDLE I NOTED EXCESSIVE BRAKE PEDAL TRAVEL AFTER PLACING MY RIGHT FOOT ON THE BRAKE. THE BRAKE PEDAL TRAVELED ALL THE WAY TO THE FLOOR BOARD AND WAS VERY SLOW IN RETURN. I SHUT THE VEHICLE OFF AND VISUALLY CHECKED THE MASTER CYLINDER AND CONNECTIONS. I NOTED THE MASTER CYLINDER BRAKE FLUID RESERVOIR WAS NOT COMPLETELY AT THE FULL MARK. I CONTINUED TO OBSERVE THE HYDRAULIC CONNECTIONS AND FOUND NO ACTIVE LEAK AND NO FLUID ON THE GROUND BENEATH THE VEHICLE. I DROVE THE VEHICLE TO A REPAIR SHOP IN TOWN (OUT OF STATE VISIT) ADVISING THE SHOP OWNER OF THE PROBLEM INVOLVING BRAKE TRAVEL. A MECHANIC DETERMINED THE BRAKE LINES ON MY VEHICLE WERE ROUTED ALONG THE VEHICLE FRAME, MADE OF STEEL, AND UNPROTECTED RESULTING IN CORROSION, HOLES, AND ACTIVE LEAKS. TWO OF THE LINES WERE REPAIRED AND NOW THE REMAINING TWO LINES REQUIRE REPAIR. I OBSERVED AND NOTED CORROSION OF THE BRAKE LINE DISTRIBUTION SYSTEM ALONG THE VEHICLE FRAME RUNNING TO THE REAR OF THE VEHICLE AND CROSSING OVER THE RIGHT SIDE. I BELIEVE THE BRAKE LINE CORRODED AND FAILED IMMEDIATELY BEHIND THE DRIVER'S SIDE LOCATED IMMEDIATELY NEXT TO THE VEHICLE IDENTIFICATION TAG. THIS LOCATION WAS OBSCURED FROM VIEW BECAUSE A PLASTIC WIRING HARNESS IS ROUTED BETWEEN THE BRAKE LINES AND EXTERIOR OF THE FRAME. I BELIEVE THE PLACEMENT OF THE PLASTIC CONDUIT CONCEALS VISION / INSPECTION OF CORRODING BRAKE LINES. I BELIEVE UNPROTECTED STEEL BRAKE LINES ARE SUBJECT TO PHYSICAL ABRASION AND MOISTURE BETWEEN THE UNPROTECTED BRAKE LINE AND THE VEHICLE FRAME RESULTING IN BRAKE LINE FATIGUE AND WATER BASED CORROSION RESULTING IN HOLES AND FAILURE OF THE HYDRAULIC BRAKE SYSTEM. I NEVER OBSERVED THE OPERATION OF THE "BRAKE" ICON LOCATED ON THE VEHICLE MESSAGE PANEL. *TR

NHTSA ID

10482767

Incident

Aug 10, 2012

Mileage

115,000 mi

THE REAR EXHAUST MANIFOLD BOLTS ON BOTH THE DRIVER'S SIDE AND PASSENGER SIDE ARE BROKE AND NOW THE VEHICLE HAS AN EXHAUST LEAK. *TR

NHTSA ID

10476574

Incident

Aug 20, 2012

Mileage

154,000 mi

TL* THE CONTACT OWNS A 2004 CHEVROLET SUBURBAN 2500. WHILE DRIVING APPROXIMATELY 50 MPH UP AN INCLINE, THE BRAKE WAS APPLIED AND SUDDENLY THE PEDAL TRAVELED TO THE FLOORBOARD. THE VEHICLE FAILED TO SLOW DOWN AND THE EMERGENCY BRAKE WAS ENGAGED TO SLOW THE VEHICLE. THE VEHICLE WAS TAKEN TO A NEARBY INDEPENDENT MECHANIC WHO ADVISED THAT THE FOUR BRAKE LINES RUPTURED DUE TO RUST AND CORROSION. THE VEHICLE WAS LEFT FOR REPAIRS. THE MANUFACTURER WAS NOT MADE AWARE OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 80,000.

NHTSA ID

10425640

Incident

Sep 14, 2011

Mileage

80,000 mi

FORWARD BRAKE LINES COMPLETELY RUSTED THROUGHOUT WHICH LED TO A LEAK AND SUBSEQUENT BRAKE FAILURE. OTHER BRAKE COMPONENTS WERE ALSO FOUND TO BE RUSTED SOMEWHAT PREMATURELY. *TR

NHTSA ID

10361649

Incident

Aug 13, 2010

Mileage

70,000 mi

SPEEDOMETER QUIT WORKING CORRECTLY IT DOES NOT GO BELOW 42 MPH AND SOMETIMES WILL NOT GO BELOW 90 MPH. *TR

NHTSA ID

10358848

Incident

Sep 27, 2010

Mileage

71,760 mi

TRUNK WILL NOT OPEN. LOCKS AUTOMATICALLY WHILE DRIVING THEN WILL NOT UNLOCK. THERE IS NO MANUAL WAY TO OPEN THE TRUNK, HENCE NO ESCAPE IN THE EVENT OF AN ACCIDENT. *TR

NHTSA ID

10311737

Incident

Nov 10, 2009

Mileage

80,000 mi

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

This service bulletin provides information for dealers/technicians on OnStar Module 2G Sunset Information.

This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.

This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.

This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed for the vehicle in question and its applications. Technician should not use the information that is provided by the antilock braking system tire size selection.

Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected modules (with some exceptions). The updating of modules is completed in parallel instead of the technician needing to update one module at a time. This allows a more streamlined approach for dealers and customers.