2002 GMC C/K Pickup

IN A LETTER DATED APRIL 20, 2005, GM NOTIFIED NHTSA THAT IT HAD DECIDED THAT DEFECTS THAT RELATE TO MOTOR VEHICLE SAFETY EXIST IN CERTAIN MODEL YEAR (MY) 1999-2002 C/K 1500 SERIES (PBR PARKING BRAKE SYSTEM) AND MY 2001-2005 C/K 2500 AND 3500 SERIES (TRW PARKING BRAKE SYSTEM) PICKUPS WITH MANUAL TRANSMISSIONS.ACCORDING TO GM, SOME OF THESE VEHICLES MAY HAVE CONDITIONS THAT CAUSE THE FRICTION LININGS TO WEAR TO AN EXTENT WHERE THE PARKING BRAKE CAN BECOME INEFFECTIVE IN IMMOBILIZING A PARKED VEHICLE.GM'S ACTION COVERS AN ESTIMATED TOTAL OF 142,585 VEHICLES.DEALERS WILL INSTALL A LOW-FORCE SPRING CLIP RETAINER FOR VEHICLES EQUIPPED WITH THE PBR PARKING BRAKE SYSTEM AND INSTALL A REDESIGNED PARKING BRAKE CABLE ASSEMBLY ON VEHICLES EQUIPPED WITH THE TRW PARKING BRAKE SYSTEM. A TOTAL OF 58 NON-DUPLICATIVE COMPLAINTS WERE RECEIVED BY ODI AND GM CONCERNING THE APPROXIMATELY 59,000 MY 1999-2002 C/K 1500 SERIES PICKUP TRUCKS WITH THE PBR PARKING BRAKE SYSTEM.THESE INCLUDED 22 ALLEGED ROLLAWAY INCIDENTS, RESULTING IN A RATE OF 38.5 ROLLAWAY INCIDENTS PER 100,000 VEHICLES.ODI IS AWARE OF 24 COMPLAINTS REGARDING THE MY 2001-2005 C/K 2500 AND 3500 SERIES MANUAL TRANSMISSION TRUCKS RECALLED BY GM, INCLUDING 5 ALLEGING ROLLAWAY INCIDENTS.THOUGH THE CONDITIONS DESCRIBED IN GM'S LETTER ARE ALSO PRESENT IN THE C/K TRUCKS WITH AUTOMATIC TRANSMISSIONS, THE ROLLAWAY RATE IN THOSE VEHICLES WAS SIMILAR TO THOSE OBSERVED IN PEER VEHICLES STUDIED BY ODI IN THIS INVESTIGATION.THIS ENGINEERING ANALYSIS IS CLOSED. FOR ADDITIONAL INFORMATION, SEE THE ATTACHED CLOSING REPORT.

ODI OPENED PE03-057 TO ASSESS PARKING BRAKE INEFFECTIVENESS IN THE SUBJECT VEHICLES.THESE VEHICLES ARE EQUIPPED WITH FOUR WHEEL DISC BRAKES THAT INCORPORATE A SINGLE-SHOE DRUM-IN-HAT PARKING BRAKE INDEPENDENT OF THE SERVICE BRAKES.COMPLAINT AND WARRANTY DATA INDICATE THAT THE PARKING BRAKE LININGS TEND TO WEAR OUT EARLY IN THE LIFE OF THE VEHICLE (AT AN AVERAGE OF 24 MONTHS IN SERVICE), REDUCING THE PARKING BRAKE SYSTEM'S TORQUE BELOW THAT NEEDED TO IMMOBILIZE THE VEHICLE.GM HAS ATTRIBUTED THIS ACCELERATED WEAR TO FOREIGN MATERIAL INTRUSION AND A FAILURE OF THE BRAKE SHOE TO PROPERLY SELF-CENTER WITHIN ITS BRAKE DRUM.EFFECTIVE WITH THE START OF MY 2003 PRODUCTION, A NEWER REDUCED FORCE HOLD-DOWN CLIP WAS INTRODUCED TO FACILITATE BRAKE SHOE DISENGAGEMENT FROM THE DRUM SURFACE.THIS PART IS ALSO AVAILABLE AT THE SERVICE LEVEL FOR THE MY 1999-2002 VEHICLES.GM HAS INDICATED THAT THE PAKING BRAKE IS INTENDED TO OPERATE IN CONJUNCTION WITH THE TRANSMISSION TO IMMOBILZE PARKED VEHICLES, AND THAT IN MANY CASES, ACCELERATED PARKING BRAKE LINING WEAR IS CAUSED BY ROUGH USE, VEHICLE MODIFICATIONS, AND DRIVING WITH THE PARKING ENGAGED. ODI HAS UPGRADED THE PRELIMINARY EVALUATION TO AN ENGINEERING ANALYSIS TO GATHER FURTHER INFORMATION CONCERNING PARKING BRAKE USAGE FACTORS AND THE CIRCUMSTANCES SURROUNDING THE SEVENTEEN REPORTED VEHICLE CRASHES.

WHILE ATTEMPTING TO STOP IN MY DRIVEWAY, I LOST BRAKING POWER... PEDAL WENT TO THE FLOOR AFTER A FEW PUMPS. BRAKE FLUID OUT ON THE GROUND. INSPECTION REVEALED REAR BRAKE LINE FAILURE BECAUSE OF CORROSION. THE TRUCK HAD 56,337 MILES AT THE TIME. IN SEPTEMBER 2011, THE FRONT LINES FAILED BECAUSE OF CORROSION WHILE OUT DRIVING ON THE ROADS. THE CORROSION WAS SEVERE OVERALL AND I HAD THE ENTIRE FRONT BRAKE LINE SYSTEM REPLACED FROM THE MASTER CYLINDER DOWN RATHER THAN THE PARTIAL BRANCH THAT HAD BURST. AT THE TIME OF THE FRONT LINE FAILURE, THE VEHICLE ONLY HAD 58,555 MILES ON IT. IT IS WORTH NOTING THAT THE CORROSION WAS ESPECIALLY SEVERE AT THE CONTACT POINTS: WHERE FASTENERS HELD THE LINES TO THE CHASSIS AND WHERE THEY MET JUNCTION BOXES/BLOCKS. THIS BRAKE LINE ISSUE APPEARS TO BE A COMMON ONE AND IS WORTHY OF THIS REPORT. WITH SO FEW MILES, I CAN'T IMAGINE WHY THIS PROBLEM IS OCCURRING. FURTHER, WITH THE COST OF THESE VEHICLES, WHY WOULDN'T GENERAL MOTORS USE CORROSION RESISTANT MATERIALS FOR BRAKE LINES? *TR

NHTSA ID

10448615

Incident

Jan 15, 2010

Mileage

56,337 mi

FAULTY DISC BRAKE ROTORS ON GENERAL MOTOR CARS AND TRUCKS. EVEN THOUGH G.M. DEALERS ACKNOWLEDGE PROBLEM REFUSE TO CORRECT WITHOUT OWNER PAYING. COULD POSSIBLY CAUSE ACCIDENT ON BRAKE FAILURE.*AK

NHTSA ID

10116744

Incident

Mar 10, 2005

GENERAL MOTORS HEAVY DUTY HITCH ON 1999-PRESENT TRUCKS & SUVS. RATED FOR 1500 LBS TOUNGE WEIGHT & 15,000 LBS TOTAL W/WEIGHT DIST. FLEXES UNDER LIGHT LOAD COMNDITIONS WHEN USING WEIGHT DISTRUBITION. POTENTIAL METAL FATIGUE AND FAILURE(TRAILER BREAKING LOOSE) NOTHING WAS DONE BY MY DEALER, I REPLACED THE HITCH MYSELF WITH AN AFTERMARKET PRODUCT.*AK

NHTSA ID

10080608

Incident

Jul 8, 2004

Mileage

18,400 mi

INSTRUMENT PANEL FAILED COMPLETELY WITHOUT WARNING. *AK

NHTSA ID

10038365

Incident

Sep 8, 2003

ONE OF OUR 2002 GMC PICKUPS WAS INVOLVED IN A FRONTAL COLLISION THAT WAS SEVERE ENOUGH TO BEND THE FRAME AND TOTAL THE TRUCK BUT THE AIR BAGS DID NOT DEPLOY. DUE TO THE AMOUNT AND TYPE OF DAMAGE I BELIEVE THERE IS A PROBLEM. I CONTACTED GM CUSTOMER SERVICE BUT THERE DID NOT SEEM TO BE ANY INTEREST. *JB

NHTSA ID

10010354

Incident

Feb 5, 2003

Mileage

9,500 mi

GENERAL MOTORS: INFORMATION PROVIDED BY BULLETIN FOR ALL 2012 AND PRIOR GENERAL MOTOR TRUCKS AND PASSENGER VEHICLES REGARDING THE ADJUSTABLE COMFORT AND CUSTOM UPHOLSTERY OF THE DRIVER AND THE PASSENGER HEAD RESTRAINT. *PE

SAAB/HUMMER/GM: DIAGNOSTIC TIPS/RECOMMENDATIONS WHEN POWER STEERING PUMP REPLACEMENT IS NECESSARY. ANALYSIS OF RETURNED POWER STEERING (PS) PUMPS THAT HAD BEEN REPLACED FOR NOISE, NO POWER ASSIST, NO OR LOW PRESSURE AND LEAKING CONDITIONS HAS INDICATED A HIGH NUMBER OF NO TROUBLE FOUND RESULTS. ALL 1997-2010 VEHICLES AND LIGHT TRUCKS; 2010 AND PRIOR HUMMERS H2/H3 AND SAAB 9-7X VEHICLES. *PE

SOME VEHICLES HAVE A BRAKE SYSTEM WARNING LIGHT IN THE INSTRUMENT CLUSTER THAT MAY NOT ILLUMINATE WHEN THE BRAKE FLUID IS LOW, WHEN THIS OCCURS, THE VEHICLE MAY NOT MEET THE PARTIAL SYSTEM REQUIREMENT OF REDUCED BRAKING CAPABILITY. *SLC