2004 GMC Sierra 2500 Brakes Problems

Brakes lines failed under truck do to rusted out lines

NHTSA ID

11442070

Incident

Nov 27, 2021

EMERGENCY BRAKES DON'T ENGAGE

NHTSA ID

11408360

Incident

Jan 11, 2021

DURING COLD MORNINGS (WISCONSIN) I START MY TRUCK AND I HAVE NO POWER STEERING AND SOFT BRAKES. IT IS MY UNDERSTANDING THAT THE POWER STEERING RUNS THE BRAKE BOOST. ALSO, IT IS MY UNDERSTANDING THAT THERE IS A SERVICE BULLETIN THAT SAYS THAT THE POWER STEERING FLUID SHOULD BE REPLACED WITH LOW/COLD TEMP FLUID. MY CONCERN IS WHAT HAPPENS IF I LOSE POWER STEERING AND BRAKES WHILE I AM DRIVING.

NHTSA ID

11297098

Incident

Dec 23, 2019

Mileage

158,500 mi

PULLING OUT OF A PARKING LOT, LOST BRAKES. STEEL BRAKE LINES BY FUEL TANK, LET GO CAUSING TRUCK TO LOOSE BRAKES

NHTSA ID

11082095

Incident

Mar 29, 2018

Mileage

63,000 mi

I WAS TRAVELING SOUTH ON I-75 HIGHWAY ABOUT 70 MPH, IN MOTION, IN NORTHERN MICHIGAN AND HAD TO STOP FAST WHEN AN ACCIDENT OCCURRED IN FRONT OF ME. I SLAMMED/MASHED MY FOOT ON THE BRAKE PEDAL ONLY TO FEEL IT FALL TO THE FLOOR, THE METAL HYDRAULIC LINE FAILED AND I NOW HAVE NO BRAKES AT ALL!! I BEGAN TO PRESS ON THE PARKING BRAKE AND DOWN SHIFT THE TRANSMISSION TO ASSIST IN THE SLOWING OF THE VEHICLE. I ALSO STEERED AROUND THE STOPPED CARS INTO THE SIDE AND DITCH OF THE ROAD. I LUCKILY HAD THE RIGHT REACTIONS BUT NOT ALL PEOPLE DO OR CANNOT ACT AS FAST. THIS IS A DANGEROUS ISSUE WITH THIS GMC SIERRA 2004. PLEASE HAVE IT RECALLED. I HAD TO HAVE THE REPAIR SHOP REPLACE ALL THE METAL BRAKE LINES AS THEY WERE CORRODED. I HAVE NEVER HAD A VEHICLE FAIL ITS BRAKE LINES LIKE THIS. MY VEHICLE ONLY HAS 48,000 MILES ON IT AND IS GARAGE KEPT SUPER CLEAN.

NHTSA ID

11018937

Incident

Aug 7, 2016

Mileage

48,000 mi

MY VEHICLE HAD BRAKE LINES REPLACE TWO TIMES WITH LESS THAN 65,000 MILES BECAUSE BREAKS STOP WORKING. FUEL LINE REPLACED UNDER 55,000 MILES BECAUSE IT MADE CHECK ENGINE LIGHT COME ON SPEEDOMETER ERRATIC,OIL PRESSURE GAUGE HIGH AND LOW,FUEL GAUGE ERRATIC UNDER 65,000 MILES. LOUD NOISE FROM ENGINE SERVICE TECHNICIAN REPORTED THE EXHAUST MANIFOLD BOLTS HAS BROKEN TO CALL A WHITE SMOKE FROM THE MOTOR. EVERYTHING HAPPENED WITH CONSIDER TO BE LOW MILEAGE IN TALKING TO GM THEY DON'T CARE BECAUSE ENOUGH REPORT HAS NOT BEEN MADE.

NHTSA ID

10953952

Incident

Jun 6, 2007

Mileage

45,000 mi

TL* THE CONTACT OWNS A 2004 GMC SIERRA 2500 HD. WHILE DRIVING 10 MPH, THE BRAKES FAILED WITHOUT WARNING. IT WAS DIAGNOSED THAT ALL THE BRAKE LINES NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 176,395.

NHTSA ID

10850446

Incident

Mar 16, 2016

Mileage

176,395 mi

IN THE PAST THREE MONTHS THE FUEL LINES NEEDED REPLACEMENT AS THEY HAD RUSTED SO BADLY THAT A LEAK FORMED. YESTERDAY WHILE PULLING MY 10,000 POUND BOAT, MY BRAKES SUDDENLY FAILED BECAUSE OF A LEAK IN THE LINE BETWEEN THE ABS BOX AND THE RIGHT FRONT WHEEL. THE CATASTROPHIC FAILURE NEARLY CAUSED ME TO LOSE CONTROL OF MY VEHICLE AND BOAT. I WAS ABLE TO DOWNSHIFT AND USE BY EMERGENCY BRAKE TO BRING THE RIG TO A STOP.

NHTSA ID

10850103

Incident

Mar 16, 2016

Mileage

107,900 mi

I LIVE IN SOUTH EAST MA. WERE SAULT IS USE ALWAYS AND IT HAS ROTTED MY BRAKE LINES AT THE ABS CONTROLL A LINE LET GO ON MY TRUCK WITH FAMILY AND MY GRAND BABIES I AM A HEAVY TRUCK OPERATOR WITH A CDL SO I KNOW NOT TO PANIC I GOT MY TRUCK STOPPED WITHOUT A CRASH BUT IF MY WIFE WAS DRIVEING OR MY YOUNG DAUGHTER THEY WOULDNT BE SO LUCKY WE IN THE SAULTING STATES SHOULD HAVE STANELESS STEAL FOR SAFTY CANT BE TO MUCH TO ASK FOR YOUNG LIFES AT STAKE OR PEOPLE WHO PANIC WHAT SHOULD I DO AT THE TIME I WAS IN THE CITY OF TAUNTON I WAS COMING TO A HEAVILY TRAVELED STREET IN RUSH HOUR TRAFIC THE BRAKE LINE TO REAR BRAKES FALLED BECAUSE OF ROT ON INSPION I SEE THEY ARE ALL ROTTING AND NEED TO BE REPAIRED I DONT HAVE BODY ROT OR FRAME ROT OF ANY KIND ALWAYS CAR WASH AFTER STORMS ON NICE DAYS.

NHTSA ID

10839852

Incident

Mar 1, 2016

Mileage

185,000 mi

TL* THE CONTACT OWNS A 2004 GMC 2500. THE CONTACT STATED THAT THE EMERGENCY BRAKE WAS INOPERABLE. THE CONTACT MENTIONED THAT THE PARKING BRAKE WAS DEPRESSED AND AN ABNORMAL NOISE EMITTED FROM THE UNDER CARRIAGE OF THE VEHICLE. THE CONTACT BELIEVED THAT THE PARKING BRAKE CABLE WAS FRACTURED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 197,000.

NHTSA ID

10746973

Incident

Jul 24, 2015

Mileage

197,000 mi

THE COMPLAINT IS THAT THE BRAKE LINES FAILED AND ARE MADE OF VERY POOR MATERIAL. THE BRAKE LINE FAILED ON MY WAY TO WORK ONE DAY ON MARCH 10,2015.

NHTSA ID

10733150

Incident

Mar 10, 2014

ON 2/1/2015, AT APPROXIMATELY 11:30 AM, I WAS STOPPING AT MY BROTHERS MAILBOX TO GET HIS MAIL WHILE HE WAS ON VACATION. WHEN I WENT TO STOP AT HIS MAILBOX, THE BRAKE PEDAL ON MY TRUCK WENT TO THE FLOOR WITH NO RESISTANCE ON THE PEDAL. I PUMPED THE BRAKES SEVERAL TIMES, PUT THE TRUCK IN NEUTRAL AND IT CAME TO A GRADUAL STOP OVER AN EXTENDED BRAKING DISTANCE OF 20 TO 30 FEET (WHICH IS SLIGHTLY UPHILL). THERE WERE NO LIGHTS LIT ON THE DASH AND THE MASTER CYLINDER WAS BETWEEN THE MAXIMUM AND MINIMUM LEVELS ON THE RESERVOIR, WHEN I EXAMINED IT AFTER THE OCCURRENCE. WE LIVE ON A DIRT ROAD WITHOUT MUCH TRAFFIC, SO I PLACED THE TRUCK IN LOW RANGE 4WD AND DROVE IT THE 1/2 MILE HOME. UPON RETURNING HOME THE TOP BRAKE LINE WHICH RUNS ALONG THE FRAME FROM THE ANTI LOCK BRAKE BLOCK BACK TOWARDS THE DRIVERS SIDE REAR OF THE TRUCK HAD RUPTURED. THE BRAKE FLUID IN THE MASTER NEVER WENT BELOW THE MINIMUM LEVEL, SO I ATTEMPTED TO REFILL IT TO SEE IF I COULD GET ANY BRAKE PEDAL PRESSURE BACK. THE PEDAL WENT TO THE FLOOR STILL AFTER MULTIPLE TRIES WITH A FULL MASTER CYLINDER. THE BRAKE LINE HAD RUPTURED WHERE IT IS ATTACHED AT A GREEN PLASTIC FACTORY HANGER. THE BRAKE LINE WAS CORRODED/RUSTED WHERE IT HAD FAILED. IF I WOULD NOT HAVE STOPPED AT MY BROTHERS MAILBOX, IT IS 1 MILE DOWN HILL ON AN APPROXIMATE 12 DEGREE GRADE TO THE MAIN ROAD. THE INTERSECTION AT THE BOTTOM OF THE ROAD IS A 90 DEGREE, T INTERSECTION IN A CREEK BOTTOM, WHERE I AM SUPPOSED TO STOP PRIOR TO ENTERING THE MAIN ROAD. WE HAD JUST CAME HOME ON 1/31/2015 FROM A 8.0 HOUR ROUND TRIP TO SEE MY SON AT COLLEGE THROUGH THE MOUNTAINS OF MARYLAND AND WEST VIRGINIA ON I-68 AND HAD DRIVEN VARIOUS MAJOR BUSY HIGHWAYS INCLUDING I-79, I-68 AND I-81. DUE TO THE AMOUNT OF FUEL WHICH WE WOULD HAVE USED, WE DECIDED TO TAKE MY OTHER SON'S WRANGLER ON THE TRIP OR I MAY HAVE BEEN SENDING THIS EMAIL FROM THE HOSPITAL IF WE WERE LUCKY. *TR

NHTSA ID

10680368

Incident

Feb 1, 2015

Mileage

102,098 mi

I WAS LEAVING A PARKING LOT, AND AS I HIT MY BRAKES, THERE WERE NO BRAKES. I LIMPED HOME, USING THE E-BRAKE AND TRANSMISSION TO KEEP THE TRUCK UNDER CONTROL. UPON INSPECTION I FOUND THE FRONT BRAKE LINE RUSTED AND LEAKING. *TR

NHTSA ID

10671448

Incident

Jan 8, 2015

Mileage

140,000 mi

ON 9-19-2014 THE TRUCK WAS STOPPED AT A RED LIGHT AND STARTED TO INCH FORWARD. SLIGHT PRESSURE ON THE BRAKE PEDAL STOPPED THE MOVEMENT. THE EVENT WAS SO QUICK AND SLIGHT I THOUGHT NOTHING ABOUT IT. I TURNED ON THE FREEWAY AND DROVE 30 OR 40 MILES BEFORE TOUCHING THE BRAKE PEDAL AGAIN. WHEN I DID IT WENT ALMOST TO THE FLOOR WITHOUT SLOWING THE TRUCK SPEED ANY APPRECIABLE AMOUNT. AT THAT POINT I KNEW I HAD A SERIOUS PROBLEM. I GEARED THE TRUCK DOWN AND WAS ABLE TO AVOID BEING INVOLVED IN AN ACCIDENT. IF I HAD NEEDED TO COME TO A FULL AND FAST STOP IT COULD EASILY HAVE BEEN A DISASTER. AN INTERNET SEARCH REVEALED GM HAS HAD THIS PROBLEM FOR SOME TIME WITHOUT NOTICE TO TRUCK OWNERS THAT IT EXISTS. AN INSPECTION OF THE BRAKE LINES WAS DONE AND INDICATED A FAILURE IN THE BRAKE LINE SYSTEM DUE TO RUST. THE FUEL LINES SHOWED THE SAME KIND OF DETERIORATION. PICTURES CAN BE PROVIDED TO VERIFY THE LACK OF ADVANCED RUST CONDITIONS TO THE UNDERNEATH OF THE TRUCK OTHER THAN THE BRAKE LINE SYSTEM, THE FUEL LINE SYSTEM, AND THE DRIVE SHAFT. THE TRUCK WAS PURCHASED NEW IN SOUTH CAROLINA AND HAS BEEN DRIVEN THERE 90% ON THE TOTAL MILEAGE ON IT. *TR

NHTSA ID

10638398

Incident

Sep 19, 2014

Mileage

180,000 mi

THIS SELDOM USED, WELL MAINTAINED, GARAGED TRUCK, BLEW OUT THE BRAKE LINES ON LEFT SIDE ON THE FRAME, UNDER THE DOOR, RESULTING IN TOTAL BRAKE FAILURE. I HAD TO USE THE PARKING BRAKE TO STOP THE VEHICLE. I WAS ON MY WAY TO PICK UP A #9000 BOAT. IF I HAD THAT BOAT BEHIND THE TRUCK, IT COULD HAVE KILLED ME, OR OTHERS ON THE ROAD. BRAKE LINES ARE NOT A NORMAL SERVICE PART. REPLACING ALL THE BRAKE LINES IS COSTING ME 1300, AT A MINIMUM. MY NEIGHBOR NEXT DOOR HAS A SIMILAR 2004 GMC SIERRA, WITH ABOUT THE SAME MILEAGE, ONLY HIS IS A 1/2 TON, WHERE MINE IS 3/4 TON. HIS TRUCK HAD THE SAME FAILURE THE WEEK BEFORE, IN THE EXACT SAME LOCATION ON THE LINES. DO A SIMPLE SEARCH LOOKING FOR BRAKE FAILURES ON THESE VEHICLES, AND YOU FIND THAT ITS WELL DOCUMENTED. THIS SHOULD BE A RECALL BEFORE PEOPLE ARE KILLED. THERE IS NO WAY THAT I SHOULD BE LOOKING AT BRAKE LINE FAILURE ON A 10 YEAR OLD GARAGED TRUCK THAT HAS A TOW CAPACITY OF OVER 10,000 #'S. HOW SHOULD SOMEONE DETECT THE INTEGRITY OF THE BRAKE LINES TO DETERMINE WHEN THE SHOULD BE REPLACED? *TR

NHTSA ID

10638025

Incident

Sep 20, 2014

Mileage

73,000 mi

BRAKE LINES RUSTED AND LEAKING. *TR

NHTSA ID

10632803

Incident

Sep 9, 2014

Mileage

71,000 mi

ALL THE FLUID LINES CORRODED TO THE POINT WHERE THE VEHICLE WAS DANGEROUS TO DRIVE WITH ONLY 35000 ORIGINAL MILES ON IT. *TR

NHTSA ID

10583638

Incident

Apr 19, 2014

Mileage

35,000 mi

BRAKE PEDAL WENT TO THE FLOOR. ALMOST IMPOSSIBLE TO DRIVE LIKE THAT. TAKES OVER 100X LONGER TO STOP A 3/4 TON TRUCK. I FOUND THAT THE BRAKE LINES RUSTED OUT. I ALSO FOUND SEVERAL HUNDRED REPORTS OF THE SAME THINGS ON GM TRUCK ONLINE. I ALSO HEARD YOU WERE INVESTIGATING THIS ISSUE ALREADY. I WANTED TO MAKE SURE I AM COUNTED AS ONE OF THE EFFECTED PEOPLE. I ALSO READ WHERE GM DOES NOT CONSIDER THIS A SAFETY ISSUE. I DISAGREE. THE LINE FROM THE MASTER CYLINDER TO THE ABS UNIT BLEW SO I HAD ZERO BRAKE PRESSURE AND PEDAL. I THINK THIS SHOULD BE RECALLED AS IT IS A HUGE SAFETY ISSUE. I HAVE ALREADY SPENT OVER $1000 AND A WEEK TRYING TO FIX THIS AND REPLACE ALL THE RUSTED LINE. I STILL DO NOT HAVE THE TRUCK BACK ON THE ROAD. THANKS *TR

NHTSA ID

10567069

Incident

Feb 26, 2014

Mileage

169,000 mi

TL* THE CONTACT OWNS A 2004 GMC SIERRA 2500. THE CONTACT STATED THAT THE BRAKE FAILED TO ENGAGE WHILE ATTEMPTING TO APPLY THE BRAKE PEDAL WHILE DRIVING 35 MPH. THE VEHICLE WAS TOWED TO A LOCAL MECHANIC FOR INSPECTION THAT CONFIRMED THAT THE BRAKE LINES WERE CORRODED. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS NOT AVAILABLE. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE AND CURRENT MILEAGE WAS 98,000.

NHTSA ID

10562816

Incident

Feb 3, 2014

Mileage

98,000 mi

WHEN ATTEMPTING TO STOP, THE TRUCK BEGAN TO STOP AND THEN ALL OF A SUDDEN THE BRAKE PEDAL WENT TO THE FLOOR. AT THIS POINT THERE WERE NO BRAKES AT ALL. THANKFULLY NO ONE WAS IN FRONT OF ME SO I WAS ABLE TO COAST UNTIL THE VEHICLE SLOWED, AND THEN USE THE E-BRAKE TO SLOW DOWN ENOUGH TO TURN. UPON FURTHER INSPECTION, A BRAKE LINE HAD BROKEN. *TR

NHTSA ID

10543984

Incident

Sep 5, 2013

Mileage

77,610 mi

TL* THE CONTACT OWNS A 2004 GMC SIERRA 2500 HD. THE CONTACT STATED THAT WHILE DRIVING 40 MPH, HE APPLIED THE BRAKES BUT THE VEHICLE DID NOT RESPOND. HE CONTINUED APPLYING PRESSURE UNTIL THE PEDAL TOUCHED THE FLOORBOARD AND FINALLY, THE VEHICLE CAME TO A STOP. THE VEHICLE WAS TAKEN TO A DEALER FOR DIAGNOSIS AND THE CONTACT WAS INFORMED THAT THE STEEL BRAKE LINES EXHIBITED MASSIVE CORROSION AND WERE LEAKING. THE VEHICLE WAS TAKEN TO A DIFFERENT DEALER WHERE THE REPAIR WAS COMPLETED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE AND CURRENT MILEAGE WAS 80,000.

NHTSA ID

10543468

Incident

Jul 31, 2013

Mileage

80,000 mi

WHILE TRAVELING ON THE PA TURNPIKE AT APPROX. 60 MPH, TRAFFIC SUDDENLY SLOWED IN FRONT OF ME. I WAS PULLING OUR 30 FIFTH WHEEL CAMPER AT THE TIME. I APPLIED THE BRAKE HARD HAD A SPLIT SECOND OF BRAKING ACTION AND THEN THE BRAKE PEDAL WENT TO THE FLOOR. I WAS ABLE TO USE THE MANUAL TRAILER BRAKE CONTROL TO SLOW THE TRUCK SOME, SWERVED INTO THE LEFT LANE MISSING THE CAR IN FRONT OF ME BY INCHES AND THE CAR TO THE LEFT OF ME SWERVED INTO THE FAR LEFT LANE TO AVOID HITTING ME. (THREE LANE HIGHWAY) I MANAGED TO DRIVE THE TRUCK TO A REST AREA ABOUT A MILE DOWN THE ROAD USING BOTH THE TRAILER BRAKES AND THE TRUCK EMERGENCY BRAKES. THE CAUSE OF THE BRAKE FAILURE WAS THAT THE BRAKE LINE LOCATED UNDER THE DRIVERS AREA HAD RUSTED THROUGH AND RUPTURED. *JB

NHTSA ID

10541983

Incident

Sep 4, 2013

Mileage

75,000 mi

EXPERIENCED A COMPLETE LOSS OF SERVICE BRAKES. FORTUNATELY THIS OCCURED AFTER COMPLETING A TRIP WHILE TOWING A TRAILER. HAD THIS HAPPENED DURING THE TRIP SERIOUS INJURIES AND MULTIPLE DEATHS COULD HAVE BEEN THE RESULT. INVESTIGATION OF THE PROBLEM INDICATED PREMTURE RUSTING THROUGH OF THE STEEL BRAKE LINE TO THE RIGHT FRONT DISC BRAKE. THE BRAKE LINE TO THE LEFT FRONT CALIPER IS ALSO BADLY RUSTED. THE BRAKE LINES FROM THE MASTER CYLINDER ARE MILDLY RUSTED AS WELL.

NHTSA ID

10537840

Incident

Aug 24, 2013

GOT IN VEHICLE, STARTED IT,PUT IN GEAR,APPLIED BRAKE AND PEDAL DEPRESSED FARTHER THAN USUAL, HIT AGAIN THEY WENT ALMOST TO FLOOR.GOT OUT AND SAW BRAKE FLUID ON FRAME WHERE LINE HAD RUSTED IN THROUGH.UPON INSPECTION ALL LINES ARE TERRIBLY RUSTED AND WILL NEED REPLACED. *TR

NHTSA ID

10534707

Incident

Aug 10, 2013

Mileage

99,600 mi

MY BRAKE LINES RUSTED AT THE REAR OF THE LT FRONT WHEEL SPLASH AREA. THIS VEHICLE HAS LOW MILES FOR THE YEAR AND WAS NOT DRIVEN IN SALT OR DEICE. THE BRAKE LINE SHOULD NOT NEED TO BE REPLACED AT THIS TIME WITH SO MUCH SERVICE LIFE LEFT. I WAS LUCKY, THE BRAKE LINE BURST IN MY DRIVEWAY. *TR

NHTSA ID

10521677

Incident

Jun 25, 2013

Mileage

44,766 mi