chevrolet silverado 2500 hd Problems

chevrolet silverado 2500 hd 2004 Complaints

SUSPENSION:REAR:SHOCK ABSORBER

rear passenger side shock absorber lower mount sheared completely away, leaving no operable shock absorber on that side of the axle. *nm

Reported in: PLEASANT HOPE MO || Crash: N || VIN #:

FUEL SYSTEM, GASOLINE

at 35000 miles the check engine light came on and the dealer replaced parts with the gas tank/fuel line due to it being 'plugged'. 10,000 miles later it happens again but no warranty and after very dissatisfying service at dealer we opted to a new mechanic. he reset the check engine light but 1 week later it was on again. then he replaced the emissions line and 3 days later the check engine light is on again. one dealer stated that excessive driving on gravel roads leads to this problem that the fuel system is not vented properly. (??) we are ranchers and the majority of our travel takes us on gravel roads. hopefully someone figures this one out so it can be fixed....

Reported in: ROSS ND || Crash: N || VIN #: 1GCHK23U44F

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL

Reported in: ROSS ND || Crash: N || VIN #: 1GCHK23U44F

POWER TRAIN:AXLE ASSEMBLY:AXLE SHAFT:SEAL

left rear-axle seal has blown a total of 4 times. the brakes were soaked with axle fluid each time and we were told that it could catch fire if brakes got hot enough. the brakes have smoked, but have not caught fire yet! the axle-seal was replaced by the manufacturer under our warranty. the axle assembly needs to be replaced to stop the problem but, the manufacturer refuses to do this. *jb

Reported in: MOULTONBORO NH || Crash: N || VIN #: 1GCHK29U54E

SERVICE BRAKES, HYDRAULIC:POWER ASSIST

(1) i was in a tight turn. i had just hauled 2 tons of feed from a feed mill 30 miles away. (2) the power steering and brakes both stopped working suddenly and with no warning. i had no control over my vehicle and had to run into a fence post to stop it. had it happened a few minutes earlier while i was on a highway, someone could have been seriously injured or killed. the truck was completely uncontrollable. (3 vehicle was towed to dealer. after two days of testing, no solution has been found. *nm

Reported in: PERKINSTON MS || Crash: Y || VIN #: 1GCHC29U34E

STEERING:ELECTRIC POWER ASSIST SYSTEM

Reported in: PERKINSTON MS || Crash: Y || VIN #: 1GCHC29U34E

FUEL SYSTEM, OTHER:FUEL INJECTION SYSTEM

i was driving down the freeway going 70 mph on my way to work during rush hour traffic in the fast lane. all of a sudden i lost power and the truck started slowing down quickly. i immediately had to try to get over and get off the freeway so that i would not get run over, which is not an easy thing to have a vehicle on the freeway during rush hour that will not go over 15 mph. this is not very safe and i could have easily have caused an accident by cars trying to swerve around my vehicle that would not accelerate. the problem was the #7 fuel injector connector, which has been replaced and i do have the old part. i am not the only one this has happened to and this should not be happening to a two year old vehicle. when this part breaks, i feel people are at risk and this should be taken care of. *jb

Reported in: MACOMB TOWNSHIP MI || Crash: N || VIN #: 1GCHK23284F

SUSPENSION:FRONT:HUB

dt*: the contact stated the vehicle's tire hubs are sealed units and could not be repacked with grease. the hub assembly was loose which caused the bearings to become defective resulting in wobbling tires. the front hubs had to be replaced twice however the service dealer could not determine why the bearings were becoming defective. also, there was oil leaking out of the egr vavle. the egr valve was replaced which corrected the problem. then vehicle was surging and would not accelerate. when the vehicle was taken to the dealer the vehicle's egr valve was replaced again which also corrected the problem. updated 11/06/06.*jb

Reported in: LEXINGTON SC || Crash: N || VIN #: 1GCHK29214E

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:GAS RECIRCULATION VALVE (EGR VALVE)

Reported in: LEXINGTON SC || Crash: N || VIN #: 1GCHK29214E

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY

dt*: the contact stated after parking in the driveway a gasoline leak was observed coming from the gas tank. the vehicle was taken to dealership who determined the gas tank must be replaced. the contact expressed that the manufacturer should be responsible for the tank replacement in a vehicle with only 58619 miles.

Reported in: INDIO CA || Crash: N || VIN #: 1GCHK23U44F

SERVICE BRAKES, HYDRAULIC

dt*: the contact stated while driving 25 mph on normal road conditions during rush hour, the brake pedal went to the floor without any brake action when braking was attempted. there were no warning signals. the vehicle was towed to the dealership who could not determine any brake problem. the vehicle was taken to the dealership three times without any diagnostic or repair. the manufacturer was contacted, and opened the case # 14336544837. the contact was called back to inform the case was closed.

Reported in: MACCLENNY FL || Crash: N || VIN #: 1GCHK23U54F

POWER TRAIN:TRANSFER CASE (4-WHEEL DRIVE)

injectors number 2 and 7 loose connector and oil pump rubbing through transfer case on chevy silverado hd2500 traveling down the highway pulling a horse trailer the truck went into limp mode and would not keep up with highway speed. had to pull over on an interstate and attempt a quick repair along the road. transfer case has not yet caused a problem, however, the aluminum residues in the case oin are very high and when pump goes through case all oil will be lost and the vehicle will stop. *nm

Reported in: NEWMANSTOWN PA || Crash: N || VIN #: 1GCHK23204F

FUEL SYSTEM, GASOLINE:FUEL INJECTION SYSTEM:INJECTORS

Reported in: NEWMANSTOWN PA || Crash: N || VIN #: 1GCHK23204F

ELECTRICAL SYSTEM: INSTRUMENT PANEL

the speedometer on my 2004 chevrolet silverado 2500hd is not working properly. with the vehicle turned off it is reading 50mph right now. i also do not get accurate speed readings while driving, which could lead to me driving to fast/slow and possibly causing injury to myself or others.

Reported in: MERCERVILLE NJ || Crash: N || VIN #: 1GCHK23204F

ENGINE AND ENGINE COOLING:COOLING SYSTEM

truck overheated forcing me to rapidly exit roadway. problem is continual, and not recognized by manufacturer as "problem" for my model of truck. *nm

Reported in: BIG BEAR CITY CA || Crash: N || VIN #: 1GCHK23284F

ELECTRICAL SYSTEM: INSTRUMENT PANEL

on first start in the morning of that date my speedometer went up to 65 mph and stayed there ever since. i have no way to go within the speed limit. *jb

Reported in: ANAHEIM CA || Crash: N || VIN #: 1GCHK23U64F

VEHICLE SPEED CONTROL

speedometer needle does not record speed accurately, resulting in vehicle traveling either much faster, or much slower than the speed indicated (onboard computer indicated i was traveling at 92 mph, while the speedometer recorded 66; another time the onboard computer indicated i was traveling 56 mph while the speedometer indicated 87). eventually, the speedometer needle pegs to 120 mph and stays there. in researching this issue, i have seen literally hundreds of complaints of this same problem. the local dealer said they have been fixing a lot of these speedometer problems; problem is with speedometer needle only (the counter weight for the needle, or the problem with the speedometers in 2003 and up chevy trucks is caused by a tiny broken gear in the actual meter movement. the gear is a small piece of cylindrical metal surrounded by a plastic gear - the gear is held in place by 3 plastic ribs. one of the ribs cracks causing an offset. if you picture the gear as a child's top - when you normally spin the top it spins straight up and down. because the rib breaks it causes the gear to be out of balance and thus the rotation then "wobbles". this causes the gear to get stuck at various locations. gm knows of this problem.. 2004 chevrolet silverado 2500 hd (also many other complaints were relative to silverado 1500). *nm

Reported in: SANDY UT || Crash: N || VIN #:

ELECTRICAL SYSTEM

speedometer malfuntioned on my 2004 chevrolet silverado 2500hd. i noticed the malfuntion on the interstate while traveling at same speed as other drivers. my speedometer was reading 50 miles per hour and the posted speed limit was 70 miles per hour. i know that the average speed on that route is between 70 and 75 miles per hour. if someone were to drive through a school zone with the speedometer reading 20 miles per hour and were to injure a child while the actual speed traveled was in the 40-45 mile per hour range it would be gm's fault. it is well known to chevy owners that there is a defect in this particular insrument cluster and well known to gm. something should have already been done, but as of today no recalls have taken effect. *nm

Reported in: MONTEVALLO AL || Crash: N || VIN #: 1GCHK29U54E

ELECTRICAL SYSTEM: INSTRUMENT PANEL

speedometer on a 2004 chevy silverado giving false readings, or no readings at all. *nm

Reported in: BRISTOL RI || Crash: N || VIN #: 1GCHK23214F

ELECTRICAL SYSTEM: INSTRUMENT PANEL

my 2004 chevy silverado's speedometer has failed to work properly. it will read 120 mph when i'm going 20 mph. dealer said it needs a new speedometer that will cost about $500.00. in researching the problem i found this to be a very common in all newer gm vehicles from about 40-50 thousand miles, just outside the warranty. there should be a recall, as this problem can be potentially dangerous-you have no idea how fast you are going. very disappointed in gm, will rethink when i buy new vehicle. *nm

Reported in: BREMERTON WA || Crash: N || VIN #: 4RACS20274N

ELECTRICAL SYSTEM: INSTRUMENT PANEL

2004 2500 hd chevrolet truck crew cab - erratic speedometer behavior. when i "googled" this - i got tons of remarks with people having this problem. to-date, no recall from chevrolet. this is a safety hazard!!*jb

Reported in: GARDNER KS || Crash: N || VIN #:

ELECTRICAL SYSTEM: INSTRUMENT PANEL

the speedometer on my 2004 chevrolet silverado 2500hd is not working properly. when the truck is turned off the speedometer reads 90 mph, and when traveling through my neighborhood it reads 120 mph. i have found this to be a very common problem on all late model gm vehicles. this is unsafe and gm should be made to repair this problem. *jb

Reported in: KNOXVILLE TN || Crash: N || VIN #: 1GCHK23174F

ELECTRICAL SYSTEM: INSTRUMENT PANEL

the needle on my speedometer is not registering the proper speed, some days it just gets stuck at the 120 mph and doesn't move. i have been told by many gm dealerships that this is a known issue for this truck. why isn't there a recall? this is not safe because i have no idea how fast i'm traveling. i have not replaced this part as of yet. *jb

Reported in: ROSEMOUNT MN || Crash: N || VIN #: 1GCHK23124F

ELECTRICAL SYSTEM: INSTRUMENT PANEL

erratic speedometer. occasionally shows incorrect, higher or lower than realistic reading. *nm

Reported in: GUYTON GA || Crash: N || VIN #:

ELECTRICAL SYSTEM: INSTRUMENT PANEL

i own a 04 chevrolet 2500 hd. a couple of months ago my speedometer got stuck on 10 mph when i was stopped. to this day it is still no working properly showing any where from 20-40 mph when i'm stopped. this results in inaccurate readings while driving. the problem still exists today.

Reported in: COVINGTON TN || Crash: N || VIN #:

ELECTRICAL SYSTEM: INSTRUMENT PANEL

instrument cluster failure. the cluster failed within the first six months and was replaced under warranty. the replacement cluster failed a year later. the service writer told me that they repair the clusters they replace and sell them as new. i was also told that they repair the specific problem with the returned cluster and that the clusters are subject to fail again. if the cluster is replaced as new it should be a new unit. i was told that the replacement cluster was sold without warranty and that it could fail again. the tech that worked on my truck said that he replaces these clusters often. *nm

Reported in: PAHRUMP NV || Crash: N || VIN #: 1GCHK23G04F

ELECTRICAL SYSTEM: INSTRUMENT PANEL

speedometer is behaving erratically. sometimes it will read within 5 or 10 mph of actual speed (sometimes high and sometimes low) and other times it will read 0 or 100+. this has caused me to unknowingly travel beyond the posted speed limits at times and is creating an unsafe driving environment. i have contacted chevrolet and they are not willing to address this issue. *jb

Reported in: GRANBY CT || Crash: N || VIN #: 1GCHK29204E

VEHICLE SPEED CONTROL

2004 silverado 2500 hd speedometer not working. it is reading 10 or 20 mph setting still in park. *jb

Reported in: MILLHEIL PA || Crash: N || VIN #: 1GCHK24U74E

ELECTRICAL SYSTEM: INSTRUMENT PANEL

speedometer on 2004 chevy silverado has failed. safety hazard. *jb

Reported in: EMMITSBURG MD || Crash: N || VIN #: 1GCHK23284F

VEHICLE SPEED CONTROL

speedometer does not register the proper speed when vehicle is in motion. speedometer registers from 0 mph to near accurate speeds. the inaccurate readings could result in unsafe operation of the vehicle that could result in risk of injury to self and others by not being able to maintain speed limit requirements.*ak

Reported in: BLACK DIAMOND WA || Crash: N || VIN #: 1GCGK29U24Z

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:ROTOR

tl*- the contact owns a 2004 chevrolet silverado 2500 with a failure mileage of 21,566. while driving the at 35 mph and coming to a stop, the brake pedal went down properly, but it did not stop the vehicle. the vehicle was taken to a dealer twice, who stated that the brake rotors had deteriorated due to the environmental conditions. the vehicle had not been repaired. the current mileage was 23,000.*ak

Reported in: TRESCKOW PA || Crash: N || VIN #: 1GCHK23UX4F

ELECTRICAL SYSTEM: INSTRUMENT PANEL

the tachometer registers incorrectly. the rpm indicator will only advance. with the engine off, it registers 5,000 rpms. also, the speedometer operates erratically. at times it indicates a lower speed than actual or no speed at all. none of these may be a safety hazard, but it makes compliance with posted speed limits difficult. *jb

Reported in: MAGNOLIA TX || Crash: N || VIN #: 1GCHK292X4E

ELECTRICAL SYSTEM: INSTRUMENT PANEL

speedometer and tachometer became erratic, then failed completely. after researching, i found that this problem is common in chevrolet / gmc trucks. it appears that this is a defective part and that chevrolet / gmc is aware of it. my local dealer wants $500.00, a cost that chevrolet should pay.

Reported in: PALMDALE CA || Crash: N || VIN #: 1GCHC23434F

ELECTRICAL SYSTEM

tl*the contact owns a 2004 chevrolet silverado 2500 hd. the contact stated that the speedometer works intermittently. the speedometer would indicate that the vehicle was traveling 35 mph when it was idle. the dealer stated that there was a defect with the electronic speedometers. the dealer did not perform the repair. the contact also stated that the rear door locks are inoperable. the dealer has inspected the vehicle. the vin was unknown. the current mileage is 53,500 and failure mileage was 47,000.

Reported in: FALLS CHURCH VA || Crash: N || VIN #:

STEERING:LINKAGES

after having the intermediate steering shaft replaced twice because of steering clunk, the 3rd replacement was a newly designed shaft, and the problem was worse after the replacement. when i took it back to the dealer, they said now the steering column needed to be replaced because a bearing had gone bad, and won't cover it because i'm out of warranty, even though the intermediate shaft problem was covered under warranty. i was told there was no way the is problem caused the column bearing to go out. i had a previous truck which gm replaced the intermediate shaft on 4 times in less than 4 years, and after doing a little research on the web, found many sites and forums where owners discuss the very same issue with the newly designed shaft making the problem worse. i think gm needs to buck up and admit they have an issue with their steering design, and replace the parts needed to make it right at no charge to the customer.

Reported in: WATERTOWN MN || Crash: N || VIN #:

STEERING:COLUMN

Reported in: WATERTOWN MN || Crash: N || VIN #:

STEERING

Reported in: WATERTOWN MN || Crash: N || VIN #:

SERVICE BRAKES, HYDRAULIC:ANTILOCK

2004 chevrolet silverado 2500hd with approimately 32000 miles needed to replace all brakes and rotors. rear rotors and pads were severely rusted and damaged. i believe it is a quality defect in either the rotors or i nthe brake system itself. this truck was bought at local dealership(poughkeepsie chevrolet). it went through nys inspection at this same local dealership. tires were rotated regularly. truck had been inspected at 25,000 miles with no indication(from dealer) that brakes were wearing. took truck in to have them look at they quoted me a price of over $1,800.00 to replace all brakes and rotors. the mechanics and service manager pointed to a pile of rotors in the back and indicated it happens all the time. further search of internet and talking to other chevrolet owners, indeed indicates that the brake system on this model year truck has not performed to a quality standard. i am an attentive person so i noticed that something was not right. others may not be as attentive and without the right attention, these brakes systems could completely fail due to this defect and cause crash and injury. chevrolet should acknowledge the defect and take corrective actions. *ak

Reported in: POUGHKEEPSIE NY || Crash: N || VIN #: 1GCHK23U44F

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:ROTOR

Reported in: POUGHKEEPSIE NY || Crash: N || VIN #: 1GCHK23U44F

FUEL SYSTEM, OTHER:FUEL INJECTION SYSTEM

2004 chevy silverado 2500 hd with fuel injectors problems customer states that they have had the fuel injectors replaced three times and wants gm to stand behind it's product**nar**cc on 8/01/06 the check engine light illuminated and the truck began to emit white smoke. the consumer took the vehicle to the dealer it was noted that the fuel injectors had high balance rates so all were replaced. in april the gauges all shut down and the truck stopped running in the desert in 100 degree weather and were informed by a second dealer fuel injectors needed to be replaced yet again. the consumer stated was preparing for a trip decided to take the vehicle back into the dealer to have the truck checked and behold a third time the fuel injectors needed to be replaced. the consumer stated would like vehicle fixed.

Reported in: SUN CITY CA || Crash: N || VIN #: 1GCHC23164F

ELECTRICAL SYSTEM

2004 chevrolet silverado 2500hd pickup that caught fire customer states that he was driving when he began to smell smoke and then noticed that sparks were coming from the front wheel**cc the vehicle became engulfed in flames. there was no cause of the fire. *jb

Reported in: BISMARCK ND || Crash: N || VIN #: 1GCHK23U94F

SERVICE BRAKES, HYDRAULIC

tl*the contact owns a 2004 chevrolet silverado 2500 hd. while driving 60 mph, the brake pedal extended to the floor when depressed. as of september 10, 2007, the dealer had not inspected the vehicle. the failure and current mileages were 24,194. *updated 12/12/2007 *bf the consumer stated replaced the master cylinder fix problem. updated 12/12/07

Reported in: PRICE UT || Crash: N || VIN #: 1GCHK29184E

POWER TRAIN:TRANSFER CASE (4-WHEEL DRIVE)

no specific event led to this incident other than faulty engineering. the pump within my trucks transfer case has worn a hole through the casing. this is a very prevalent problem in this model truck. i have this problem temporarily patched. i just noticed the problem a couple of weeks ago. here's an example of the problem: http://adaptacase.com/tc236cbrny.html *jb

Reported in: HOWELL MI || Crash: N || VIN #: 1GCHK23234F

ENGINE AND ENGINE COOLING:ENGINE:DIESEL

tl*the contact owns a 2004 chevrolet silverado 2500 hd. while driving uphill at 55 mph, the engine failed without warning. the contact was able to coast to the side of the road. he reprimed the fuel filter and the vehicle drove approximately a mile and a half before it shut off again. he had to reprime the filter again. the contact pulled over to allow the vehicle to cool off. the vehicle was taken to a service station and the mechanic spoke with chevrolet, who was not aware of any recalls. the current and failure mileages were 95,000. *updated 12/27/07 *lj updated 12/12/07

Reported in: SURPRISE AZ || Crash: N || VIN #: 1GCHK23174F

FUEL SYSTEM, DIESEL

Reported in: SURPRISE AZ || Crash: N || VIN #: 1GCHK23174F

ELECTRICAL SYSTEM: INSTRUMENT PANEL

tachometer & speedometer failure at low temperatures

Reported in: YUMA AZ || Crash: N || VIN #:

ELECTRICAL SYSTEM: INSTRUMENT PANEL

speedometer reads improperly. you look down and your going 110 this makes you want to slam on your brakes. how safe would that be on a interstate? *jb

Reported in: MOORESVILLE NC || Crash: N || VIN #: 1GCHK29G44E

SERVICE BRAKES, HYDRAULIC:ANTILOCK:WHEEL SPEED SENSOR

2004 silverado 2500 hd abs kicks in at slow speeds. now abs light and brake light are always on and i get dinging sound from warning system with message service brake system.

Reported in: YORK NY || Crash: N || VIN #: 1GCHK23254F

ELECTRICAL SYSTEM: INSTRUMENT PANEL

2004 silverado 2500 hd abs kicks in at slow speeds. now abs light and brake light are always on and i get dinging sound from warning system with message service brake system.

Reported in: YORK NY || Crash: N || VIN #: 1GCHK23254F

ELECTRICAL SYSTEM: INSTRUMENT PANEL

speedometer readings are inaccurate. gm issued special warranty coverage for vehicles with less than 70,000 miles. my issue was reported to the dealer at 58,000 miles, but was not documented in their system. speedometer readings are erratic. sometimes accurate, sometimes 50% or more less than actual speed. inaccuracy has increased over the last year.

Reported in: THOMPSON ND || Crash: N || VIN #: 1GCHK23114F

POWER TRAIN:DRIVELINE:DIFFERENTIAL UNIT

bearing in front axles came apart. causing metals to go through all of the front differential drivetrain. complete front drivetrain needed to be replaced. truck was 1500 miles and 2 months out of warranty and dealer could do nothing to help out with cost of repair. this bearing should have not came apart. fluid levels were good, no leaks, and maint per manufacturers schedule was always performed.

Reported in: WESTBROOK ME || Crash: N || VIN #:

SERVICE BRAKES, HYDRAULIC:ANTILOCK

my 2004 silverado 2500hd has developed the following brake concern for the past year. when stopping as the truck slows to around 10 mph the brake pedal pluses and drops to a very low position that results in extending the stopping distance. all four rotors & pads have been replaced along with removing cleaning of the wheel speed sensors. the problem continues and i have had some close calls that could have resulted in a rear end collision.

Reported in: FAIRPORT NY || Crash: N || VIN #: 1GCHK29U84E

ELECTRICAL SYSTEM: INSTRUMENT PANEL

speedometer will change from a correct reading to a erroneous reading with no warning. if i turn on and off the vehicle, the speedometer will reset back 5 mph each time i do this until rest to 0mph at a stand still. it will then correctly operate for varying amounts of time (50 - 500 miles) before it goes haywire again. gm acknowledges that this is a known problem and has a policy in place to repair at no cost if vehicle is 7 years old or less and less than 70,000 miles. my problem is that my vehicle is a 2004 with now 144,000 miles on it and gm will do nothing. initially i contacted them on my own and was declined. after i sent a letter to the attorney general's office in mn, gm contacted me and for a second time denied helping correct this problem. i'm contacting you at the direction of the mn attorney generals office. bottomline is that the speedometer is not a convenience feature but a necessary feature required to safely operate the vehicle. gm acknowledges that it is enough of an issue that they have a policy to repair outside of factory warranty however feel that my 3 1/2 year old $50,000 vehicle is precluded from the same consideration of a vehicle with less than 70,000 miles on it. dealers i have spoke to tell me that this problem is so common that they repair these daily.

Reported in: WYOMING MN || Crash: N || VIN #: 1GCHK23214F

ELECTRICAL SYSTEM: INSTRUMENT PANEL

speedometer stopped working properly . i have several tickets for speeding now. i had it checked at 50,000 miles and could not afford to fix it. i now have 80,000 miles and chevy won't replace my instrument panel. i feel this is a safety issue. i also had to replace the front hub assembly already.

Reported in: OAK HILL FL || Crash: N || VIN #: 1GCHK29194E

ELECTRICAL SYSTEM: INSTRUMENT PANEL

tl*the contact owns a 2004 chevrolet silverado 2500 hd. the speedometer dial is normally at 0, even when the vehicle is in motion. in march of 2007, the speedometer completely failed. the manufacturer stated that they would correct the failure for free if the vehicle was at 80,000 miles or below. the dealer stated that the electrical system needed to be replaced at the cost of $700. the current mileage was 118,000 and failure mileage was 63,000.

Reported in: PORTLAND TN || Crash: N || VIN #: 1GCHK24U94E

FUEL SYSTEM, GASOLINE:FUEL INJECTION SYSTEM:INJECTORS

tl*the contact owns a 2004 chevrolet silverado 2500 hd. while driving 65 mph, he saw smoke coming from the tail pipe. the dealer stated that the injectors caused the failure. as of january 11, 2008, the dealer had not repaired the vehicle. the failure mileage 87,900 and current mileage was 88,546.

Reported in: TULSA OK || Crash: N || VIN #: 1GCHK23104F

ELECTRICAL SYSTEM: INSTRUMENT PANEL

speedometer and tachometer have fails at 35,000 miles in 2004 chevrolet silverado 2500hd.

Reported in: LARAMIE WY || Crash: N || VIN #:

SUSPENSION:FRONT:HUB

there was a bumping noise noted coming from the left front wheel. the truck was taken to the dealer for repair. the left front hub assembly for the chevy 2500hd four wheel drive with duramax diesel engine was replaced. the dealer stated that the right front hub assemble was also loose and would need to be replaced soon. the dealer stated that they have had to replace three other complete hubs, so this means that a total of six hubs have had to be replaced. it was confirmed with the dealer that these hub assemblies have no grease fittings and only come with whatever grease is in the hub at the time of manufacture. this is a potentially dangerous situation and could result in an accident with a loss of life. this is reported in the hope that a full and complete investigation is conducted prior to a catastrophic failure with a loss of vehicle control and a resulting loss of property and lives. this should be investigated with the highest priority. i await your response and results of the investigation.

Reported in: FORT PAYNE AL || Crash: N || VIN #: 1GCHK23124F

SERVICE BRAKES, HYDRAULIC:POWER ASSIST:HYDRAULIC

brake failure 2004 silverado 2500hd duramax. hydro boost exploded which renders limited steering and brakes. this known problem 05v043000, 04v045000, for these trucks not only is a bad design but it is a hazard to the owner, mechanic and innocent occupants of other vehicles sharing the same roadway.

Reported in: MANSFIELD TX || Crash: N || VIN #: 1GCHK23284F

ELECTRICAL SYSTEM: INSTRUMENT PANEL

speedometer and tachometer have both failed. with the key off it reads 4200rpm and over 120mph chevy knows of this problem and wont cover it because i have over 70,000 miles. but they know the problem is there and i would think not knowing your speed is a safety issue. it will cost me over $400.00 to fix this and i think chevy should be responsible for this cost.

Reported in: KENOSHA WI || Crash: N || VIN #: 1GCHK23174F

ELECTRICAL SYSTEM: INSTRUMENT PANEL

i purchased a 2004 chevy 2500 hd last fall and now my instrument cluster is sticking and on occasion giving false readings. the needle of the speedometer was stuck on several occasions and the rpm needle does not read accurately> i don't even know if any of the other gauges are working properly. so far i have not had a speeding ticket, but with the gauges not working who knows how long.

Reported in: FREEMAN SD || Crash: N || VIN #: 1GCGK23U94F

AIR BAGS

tl*the contacts son owned a 2004 chevrolet silverado 2500 hd. while driving approximately 60 mph on a 60 mph curve, the vehicle flipped forward several times. it struck a fence before being stopped by a tree. the contacts son was partially ejected from the vehicle. the air bags failed to deploy. her son was transported by helicopter to a local hospital where he passed away hours later. a police report was filed. the vehicle was destroyed. the manufacturer has not yet been notified. the current and failure mileages were 35,000. updated 3/25/08 *cn texas crash report. updated 03/25/08

Reported in: WALLER TX || Crash: Y || VIN #: 1GCHK29284E

ELECTRICAL SYSTEM: INSTRUMENT PANEL

instrument panel failure in 2004 chevy silverado 2500hd the panel is required by law isn't ? chevy is very unco-operative with this if you have over 70,000 miles but as far as my experience goes you can and will get a ticket for an inop speedo. mine will hang up past 120mph and even when not running the rpm will read 4500. this is absolutely a safety issue and chevy should eat the replacement cost of $450.00.

Reported in: KENOSHA WI || Crash: N || VIN #:

SERVICE BRAKES, HYDRAULIC

i bought new a 2004 chevy. silverado 2500hd extended cab 4x4 pickup with the 6.0 liter gas engine. it currently has only 37,000 mi on it and is garage kept in wi. from when i first bought it i thought the brake pedal was a bit soft(went down too far) but was told that was normal from the chevy dealer. ever since it has gotten much worse. at times now the pedal goes almost all the way to the floor and i am afraid i am going to hit something. often, when the speed finally gets down to under 10mph the brakes then pulse as if the abs is activated and the other day i almost hit the car ahead of me after almost being stopped before the brakes started pulsing. i am 46yo, am a police officer, and drive for a living during my normal work day. i have many years and much experience driving and i can tell you, these brakes are not functioning correctly and will cause me, if not others to have a bad accident. i am afraid to even drive this vehicle very far and certainly would never tow anything with it. i think chevrolet and gm are avoiding the problem because it will be a potentially big recall and will cost them more money than lawsuits. (actuaries have probably done the math) this problem should be looked into and addressed before people needlessly die. note: this has been an ongoing problem since the vehicle was new but has continually gotten much worse. the incident date below does not reflect the time over which the problem has been present. i know other people with chevy and gmc trucks that have expressed the same problem to me. please look into this!!!

Reported in: POYNETTE WI || Crash: N || VIN #: 1GCHK29U14E

FUEL SYSTEM, DIESEL

tl*the contact owns a 2004 chevrolet silverado 2500 4x4 diesel. while driving various speeds, the vehicle would misfire. the next misfire would recur 45 minutes later, and the third misfire would normally recur an hour afterwards. the failure was intermittent. the contact could not drive over 25 mph and the vehicle constantly jerked. in january of 2008, she took her vehicle to the dealer and they replaced two fuel injectors. on april 2, 2008, the dealer replaced 8 fuel injectors. after the most recent failure, the contact took the vehicle to the dealer for a diagnostic. they could not locate any failures. the failure mileage was 65,000 and current mileage was 97,000.

Reported in: GROVE OK || Crash: N || VIN #: 1GCHK23224F

ELECTRICAL SYSTEM

intermittently shift display and door locks not working. when shifting from reverse to drive, the truck would buck. locks would not unlock when put into park. check engine light kept coming on. code p0708 in system for park/neutral switch. replace park/neutral switch for a total of $416.48.

Reported in: NASHUA NH || Crash: N || VIN #: 1GCHK23134F

LATCHES/LOCKS/LINKAGES

Reported in: NASHUA NH || Crash: N || VIN #: 1GCHK23134F

ELECTRICAL SYSTEM: INSTRUMENT PANEL

speedometer quit working.

Reported in: ALLEN TX || Crash: N || VIN #: 1GCGK23U14F

ELECTRICAL SYSTEM

taking my son to school and while driving past the high school, i noticed my speedometer was showing me driving over 70 mph. concerned that i was traveling too fast and worried about getting a ticket, i slowed very drasticly to slow down to the posted (during school hours speed limit), causing a near traffic accident from vehicle behind me. mean while, young high school student were distracted while crossing the road because of my abrupt speed change. after slowing down, i notice that while almost stopped, my speedometer was continuing to show speeds over 50mph. this all happened with my milage showing around 85,000 miles. the next day, i recieve a notice from gm saying that the vehicle may experiance speedometer problems and that gm will repair the problem with vehicles less than 70.000 miles. since then i have been to the dealers and have heard price from $750 to $1200 to fix the problem. i have been driving very careful and been waiting for gm to recall all trucks with the problems. i am tried of waiting and feel that i am at risk for not having the proper speed shown. meanwhile, my oil pressure gauge is failing which cause enging alarm to sound and i can no longer trust my fuel gauge because it will show half full when it is completely empty. these are all safety problems in my eyes.

Reported in: CITRUS HEIGHTS CA || Crash: N || VIN #: 1GCHC23164F

SERVICE BRAKES, HYDRAULIC

2004 chevy silverado electronic brake control module and brake pump are both inoperative with 25,000 miles on the vehicle.

Reported in: CONROE TX || Crash: N || VIN #: 1GCHC24U14E

FUEL SYSTEM, GASOLINE

at approx 65,000 miles my speedometer stopped working along with other gauges in the instrument panel. gm refused to fix the problem. when i had 80,000 miles gm offered to fix the defect only on vehicles with less than 70,000 miles. they refused to correct the defect on my vehicle. the dealer estimates the cost to fix this defect at approx $450.00 i now have approx 105,000 miles and continue to drive without a working speedometer. this vehicle and many with this same defect is used for towing. gm has put profit ahead of safety and customer satisfaction. the ntsb has continued to allow thousands of vehicles to operate unsafely with this well known and documented defect by failing to force gm to recall these vehicles many of which were still being manufacture after the defect was discovered.

Reported in: BEAUMONT CA || Crash: N || VIN #: 1GCHC29U94E

ELECTRICAL SYSTEM

Reported in: BEAUMONT CA || Crash: N || VIN #: 1GCHC29U94E

TIRES

i have a set of mastercraft courser a/t (cooper tires). the dot # is 3dyu 0705 2g13l. two weeks ago i had a large bubble on one tire and had it replaced. today i had another one where the tread blew out causing me to wreck. the tire store has said that the tread / metal seperated on both tires.

Reported in: WEATHERFORD TX || Crash: Y || VIN #:

ELECTRICAL SYSTEM: INSTRUMENT PANEL

i was driving, going about 55 mph, when i looked down at my speedometer and it showed that i was going about 135mph. now, with the vehicle parked, with the key on, it still shows that i'm going 70 mph. the vehicle has only 34,600 miles on it, and gm says they will repair it free, up to 70,000 miles, which is fine, but they (gm) won't recall these trucks because its not a safety matter. if you are exiting an interstate highway with a sharp turn rated at 35mph and you don't have a working speedometer it could be tragic. just check the internet about if there are recalls of these trucks will show this problem is widespread. thanks

Reported in: INGRAHAM IL || Crash: N || VIN #: 1GCHC29U24E

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

three exhaust manifold bolts head snapped off, resulting in dangerous exhaust being expelled under the hood.

Reported in: DERBY CT || Crash: N || VIN #: 1GCHK29U64E

POWER TRAIN:DRIVELINE

at around 60,000 miles the following occurred. no specific event led to this incident except the transfer pump came loose. when the pump dropped down, this allowed the drive shaft to wear the transfer casing as well. the transfer case and the drive shaft yoke had to be replaced. this was not covered by the warranty.

Reported in: JAMESTOWN OH || Crash: N || VIN #: 1GCHK24194E

ELECTRICAL SYSTEM

the dash board gauges stopped work. i was driving down the road and the gauges dropped down to 0.

Reported in: HOLBROOK MA || Crash: N || VIN #: 1GCHK23234F

STEERING

knocking in steering column. was lubricated once, problem persists. low speed knocking and "looseness" in steering wheel. knocking is quite loud and evident when turning, at low speed, or if encountering any bumps in road surface.

Reported in: KANAB UT || Crash: N || VIN #: 1GCGK23424F

SUSPENSION:FRONT

drivers side front wheel bearing failed, also triggered abs problems as sensor is in wheel hub.

Reported in: TALENT OR || Crash: N || VIN #: 1GCHK29234E

SERVICE BRAKES, HYDRAULIC

parking brake cable that runs next to drivers side frame has a part that connects two pieces of the cable together right below the drivers side door. this part is not smooth and causes snow buildup around the cable connector which then weighs down the cable causing the parking brake to inadvertently activate.

Reported in: TALENT OR || Crash: N || VIN #: 1GCHK29234E

POWER TRAIN:TRANSFER CASE (4-WHEEL DRIVE)

transfer case develops hole from pump inside on my 2004 chevy 2500 hd duramax. sounds like this is a very common problem with gm owners with this type of transfer case. its being called the infamous pump rub. sounds like gm is ignoring this problem. this should not be happening on vehicles this new with little miles on them.

Reported in: BELLEVILLE WI || Crash: N || VIN #:

ELECTRICAL SYSTEM: INSTRUMENT PANEL

faulty speedometer on 2004 silverado. problem started outside of normal warranty and finally completely failed outside of extended warranty through lawsuit. just paid for it to be fixed at a cost of $525. gm should have to pay for this.

Reported in: HASLET TX || Crash: N || VIN #: 1GCHK23104F

FUEL SYSTEM, DIESEL

fuel gauge at fill up went past full and completely clock wise...gauge reading is all over the place everytime i start engine. vehicle has 59,000 miles. i have to read my "range" reading, (uncertain of accuracy)to approximate fuel in diesel tank.

Reported in: ROYAL PALM BEACH FL || Crash: N || VIN #: 1GCHK23294F

ELECTRICAL SYSTEM

speedometer fails to register correct speed. remains at zero while driving and needle jumps erratically.

Reported in: FOSTER RI || Crash: N || VIN #: 1GCHK23124F

ELECTRICAL SYSTEM: INSTRUMENT PANEL

today driving home my cable was at 65 mph in a 40 stopping noticed that the speedometer cable would not go down went to local repair shop and told about the recall called chevy dealer and yes the same 70000 miles. when i purchased this vehicle it had more then 70,000 miles so i get penalized for the purchase ! looks like chevy should stick by there products and bring a recall for all the pickups !!

Reported in: PLAINVILLE KS || Crash: N || VIN #: 1GCHK29U54E

ELECTRICAL SYSTEM: INSTRUMENT PANEL

speedometer not working properly all the time. can be doing 25 mph and all of the sudden speedometer goes to 60mph. it will not reset until i stop and turn truck off and on numerous times. sometimes it will be pegged over 120 mph when on the highway and i am only doing 65mph.

Reported in: KENHORST PA || Crash: N || VIN #:

ELECTRICAL SYSTEM

i have had multiple issues interior wise with replacing different electrical components in the vehicle going out or not functioning correctly. i replaced the duel heater switch the radio and a/c switches. i also was having an issue with the automatic 4wd shift that would engage on its own. then my instrument cluster (gauges) started to stick. different ones at different times. now till this date the speedometer is stuck at 5 mph. i received a letter from a lawyer stating that a lawsuit had been brought up to get this corrected and to take my truck in but once i had received it and took it in they said that it was 500 miles over the mileage and would not fix it. i would think that this is still a safety issue and part of the state of texas inspections. need some help please to get this rectified.

Reported in: WYLIE TX || Crash: N || VIN #: 1GCHK23U04F

SERVICE BRAKES, HYDRAULIC

brakes fail or have reduced stopping when coming to stop dealer diagnostics as fluid leaking past accumulator valve. in order to repair,would need hydro boost replaced. 2004 chevrolet silverado,duramax diesel with allison automatic trans. was told by dealer there were 2 recalls on this vehicle type for brake hydroboost, but that my concern was not included because no external leak. also, was informed no help at this time to repair

Reported in: ST PAUL MN || Crash: N || VIN #: 1GCHK23274F

ELECTRICAL SYSTEM

speedometer and tachometer indicate erratic speeds, they will lock up at anywhere from 40 to 120mph and 4 to 6000 rpm, has been acting this way for the last 5 months, usually at highway speeds. purchased from original owner sept 2008 with 84,000 miles on it, don't know if it was an existing problem or not, dealer says it is out of warranty and is not covered. safety issue for speedometer, or other gauges should they fail (fuel, oil pressure etc).

Reported in: SOUTH MILWAUKEE WI || Crash: N || VIN #: 1GCHK23G54F

ELECTRICAL SYSTEM: INSTRUMENT PANEL

my speedometer is reading the wrong speed in my 2004 2500hd chevy.

Reported in: HASLET TX || Crash: N || VIN #: 1GCHK23U04F

SERVICE BRAKES, HYDRAULIC

in oct.2008 i brought my 2004 chevrolet silverado 2500hd to poughkeepsie chevrolet in poughkeepsie, n.y. for an oil and filter change and n.y. state inspection. while waiting for the work to be completed i was ask to come and look at the vehicle while it was on the lift. i was shown the four brake rotors (still on the vehicle). the insides of the brake rotors were extremely damaged with rust, would not pass inspection and needed replacement. when i expressed my dismay and disgust (the vehicle only had 28.5k miles on it) i was told this had occurred "because the vehicle wasn't driven enough and we live in the rust belt". anyway i authorized the work to be done, i needed the n.y. state inspection and it was obvious the brakes were unsafe. after dwelling on this, i decided to do some research and came to find that the brake systems in many gm light trucks have been problematic for several years and given similar responses varying slightly to fit gm's needs to mask the root of the problem, the majority being rust and corrosion. it is obvious gm remains in denial of this defect and refuses to correct or reimburse for replacement. my first regret is allowing gm to do the work. from what i have read, previous victims that replaced their rotors with gm products had the same subsequent result. i can't believe they have not been sued. i will never buy a new gm vehicle again. it is no wonder they are going bankrupt. their problem is not the pay and benefits they give their workers, it is where they cut corners in their product (cheap material & outsourcing) to line their ceo greedy pockets. they couldn't care less about the public safety.

Reported in: WAPPINGERS FALLS NY || Crash: N || VIN #: 1GCHK24U74E

ENGINE AND ENGINE COOLING

this is how it started.. i have a 2004 chevy silverado 2500 hd. as i drove down the road the doors would lock and unlock on their own, and the truck would lose rpm's and would act as if the truck shut off and restarted itself. also the check engine light would blink with the locking and unlocking of the doors. did this off and on a few times as we babied it home. got it home in the driveway and it threw 2 codes camshaft position sensor high volts and low volts. so we replaced the camshaft position sensor. truck drove fine for 4 days. however on the 5th day we attempted to drive the truck and as we were driving down the road this time the engine light came on and stayed on and doors started locking and unlocking again on their own as well as the dic read service brake system and the truck completely died in the middle of traffic, we were able to pull over into a parking lot and truck restarted long enough to get home. at this point the gm dealer wasn't sure of this problem and what causes it but stated to unplug the battery and reset the computer(after speaking to 4 different gm dealers mind you). wow low and behold fixed the problem for about 45 minutes, as we again tried to see how far we could make it before it started acting up again. only this time doors would lock and unlock and all kinds of weird things were going on, for example doors locking and unlocking, truck stalling and restarting, idol was ruff and noisy, service engine light came on and stayed on, and the dic read this time reduced engine power!! and at this point we were only able to go 15 miles an hour and thankfully we were on a road with no traffic and were about 2 miles from our home. also in the mist of all of this the truck was chiming and the truck thought it didn't have any brakes at this point thankfully we were able to get the truck to come to a complete stop. we have had this truck for less than 1 yr and it only has 82,000 on it and noone seems to be able to tell us what is wrong with it.

Reported in: RAWLINS WY || Crash: N || VIN #: 1GCHK23U24F

ELECTRICAL SYSTEM

Reported in: RAWLINS WY || Crash: N || VIN #: 1GCHK23U24F

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

bolts sheared on the exhaust manifold.

Reported in: METHUEN MA || Crash: N || VIN #:

SERVICE BRAKES, HYDRAULIC

i own a 2004 chevrolet silverado and have a pulsating action in my abs brakes when coming to stops at slow speeds. i have already replaced all four brakes and rotors and it did not change the problem. i only have 50,000 miles on my truck. i live in pennsylvania and saw on the internet that there is a recall on some vehicles a little older than mine but not my year of vehicle. i have the same problem as all of these other people. this has been happening for quite some time now.

Reported in: DUSHORE PA || Crash: N || VIN #: 1GCHK23U44F

ELECTRICAL SYSTEM

driving at 55 mph, the speedometer needle went to 5 mph, then to 0. later in the same trip, with the cruise control at 60, (verified by gps), speedometer showed speeds from 50 down to 8mph. no warning before failure, except for a barely noticeable tremor or lack of smoothness in the speedometer needle. the truck has only 36000 miles on it. on next drive, speedometer was ok for the 20 minutes. the drive after, random speeds from startup. no corrective work done yet, but it seems that the servo motor driving the speedometer, or the entire gauge cluster has to be replaced.

Reported in: MORGAN HILL CA || Crash: N || VIN #: 1GCHK23234F

ELECTRICAL SYSTEM: INSTRUMENT PANEL

speedometer provided false readings.

Reported in: MILLBRAE CA || Crash: N || VIN #: 1GCHK29254E

ELECTRICAL SYSTEM

the speedometer has gone about 30 mph over speed should be going. it is saying the truck is doing 35mph while parked. this is a problem chevrolet is aware of but only covers trucks up to 70,000miles. our is less than 20,000 over. how safe can it be to not know how fast you are going. has started to do it in the past but now we are stuck not knowing our speed.

Reported in: LEBANON OR || Crash: N || VIN #: 1GCHK23U34F

SERVICE BRAKES, HYDRAULIC

i own a 2004 chevy silverado with approximately 52000 miles on it. when trying to come to a stop the abs brakes pulsate and the pedal drops to the floor, resulting in poor braking distance or stopping in general. i have put new rotors and pads on front and back axles and it did not help. now i find that there is recall on previous year silverado. i believe that this recall needs to be extended because my pickup is a 04 and it has the same problem. i'm afraid somebody is going to get hurt or maybe worse. this is a serious problem. it happens all of the time.

Reported in: DUSHORE PA || Crash: N || VIN #: 1GCHK23U44F

ELECTRICAL SYSTEM

speedometers on my 2004 chevrolet silverado and my 2004 chevrolet trailblazer are defective. the silverado does not register the correct speed and the trailblazer does not register at all. both vehicles have over 70,000 miles and gm refuses to fix them. the speedometer is a safety appliance and should be working correctly, no matter what the mileage of a vehicle. this should be fixed by gm at no expense to the vehicle owner !!

Reported in: RIO VISTA TX || Crash: N || VIN #: 1GCHC29U44E

ELECTRICAL SYSTEM

2004 chevy silverado 2500 hd i had speedometer issues prior to the warranty going out. at the time i initially noticed the issue it was taken in for evaluation and i was told it was going to be over 700 dollars to fix. it wasn't 6 months later i got notice that it was covered under a recall. unfortunately by then the mileage was well out (seeing i traveled for work), and i was still responsible for the bill. i feel its a very unfair process in which i was told it was my responsibility and then had things gone at a faster rate at that time, it would have been covered. i still have this issue as do many others.. shouldn't it still be covered no matter the miles? it's still safety affiliated!

Reported in: CONCORD GA || Crash: N || VIN #: 1GCHK23274F

FUEL SYSTEM, DIESEL

tl* the contact owns a 2004 chevrolet silverado 2500 hd. while driving he saw smoke coming from the tail pipe, and then he smelled a burning odor. the vehicle was taken to the dealer for inspection. the technician concluded that the thermostats are not allowing the vehicle to achieve operating temperature and injectors 5, 6, 1 are defective. the repair will be performed at the owners expense. the failure mileage was 102000. the current mileage was 103000.

Reported in: RHINELANDER WI || Crash: N || VIN #: 1GCHK292X4E

WHEELS

the right front wheel hub failed after i bought the truck in february 2005. the left front wheel hub failed in february of 2007 and now the left front wheel hub has failed again in november of 2009.

Reported in: WALTERBORO SC || Crash: N || VIN #: 1GCHK23294F

ELECTRICAL SYSTEM

speedometer went crazy. said i was going 120mph when i was going 60. come to find out, there are many other people that have experienced this, along with failure of the other instruments in the cluster as well.

Reported in: MUKWONAGO WI || Crash: N || VIN #: 1GCHK29U04E

ELECTRICAL SYSTEM: INSTRUMENT PANEL

the gauge clust go nuts i will be doing 40 miles per hour then i look at my seed and it says 120 and gets stuck and no one wants fix it because there may be a recall on it so where is that recall or is it that it has to cause someone's life over it before something is done about it!!!

Reported in: PHILLIPSBURG NJ || Crash: N || VIN #:

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS

while braking going downhill to a stop sign brake pedal went to the floor and i proceeded to enter into the oncoming lane. failure occured once the brake line was rusted thru and burst. no i do not have the old part but have the invoice.

Reported in: COATESVILLE PA || Crash: N || VIN #: 1GCHK23UX4F

FUEL SYSTEM, DIESEL

fuel injectors go bad causing engine to stall and lurch forward while idling. the truck has been to the dealer and had this problem repaired 3 times and is doing it again *cn

Reported in: LITTLE MOUNTAIN SC || Crash: N || VIN #: 1GCHK23224F

POWER TRAIN:DRIVELINE

2004 chevy silverado hd 2500 diesel--transfer case wearing from inside out i took my truck in to have service work done on it, and found out from the jasper transmission company, that they are doing a large number of chevy transfer cases because they weren't shimmied right from the factory, causing the gears in the transfer case to eat through the bottom of the housing on the transfer case itself. this then results in the transfer case fluid to leak out, and causes the gear box to come apart inside the transfer case. the chevy dealer that i took my truck to never even mentioned this to me, and was very evasive about the whole issue. i will never buy another gmc (gov't. motors corp.) car or truck again!!

Reported in: EDINBURG VA || Crash: N || VIN #: 1GCHK232X4F

POWER TRAIN:AUTOMATIC TRANSMISSION

Reported in: EDINBURG VA || Crash: N || VIN #: 1GCHK232X4F

STEERING

clunking and looseness in steering column. 2004 6.0 liter hd 2500 chevrolet. feels like steering may fail on vehicle if something is not corrected.

Reported in: PARIS TX || Crash: N || VIN #: 1GCHC29U34E

ELECTRICAL SYSTEM: INSTRUMENT PANEL

speedometer on 2004 chevy silverado 2500hd started acting erratically at 56,000 miles.

Reported in: SHELTON CT || Crash: N || VIN #: 1GCHK29U64E

UNKNOWN OR OTHER

gm pick up trucks have what in my opinion is a safety issue with instrument clusters failing. one can be cruising along and all of a sudden the speedometer goes crazy. mine registers 120 mph at all times. it puts one in unknown territory when in heavy traffic not to mention not knowing when one is speeding. further one does not how much fuel they have or if their vehicle is overheating. gm sent letters to owners of these vehicles indicating that they would replace the cluster if it went bad before 72000 miles.they know that any or all of the clusters are prone to failure and gm should be required to issue a recall and correct this problem at no cost to the owner.the local gm dealer tells me that it is about a $300. fix.gm should not be allowed to get away with selling vehicles with such potential safety issues.

Reported in: CEDAR BLUFF VA || Crash: N || VIN #: 1GCHK23274F

ELECTRICAL SYSTEM

Reported in: CEDAR BLUFF VA || Crash: N || VIN #: 1GCHK23274F

SERVICE BRAKES, HYDRAULIC

2004 chevrolet silverado 2500hd has severly rusted brake lines and rotors which could lead to brake failure. brake lines should not rust away in a few years and only 11000 miles

Reported in: HAZLETON PA || Crash: N || VIN #:

TIRES

complete sudden tire failure sigma tire stampede radial as lt265r75/16, dot upw8 twt 3206 cp g04l the tire had about 28000 miles on it while mounted on my chevrolet 2500 four wheel drive crew cab truck right front wheel, and had 1/3 to 1/2 of the original tread remaining. i was on i-26 in south carolina traveling at about 70 mph. i felt a very slight vibration, just slightly different than normal road vibration and about 15 seconds later, the right front tire completely disassembled. the tread separated from the tire body between the two steel belts. fortunately i was in the right lane in light traffic, and was able to bring the truck under control without hitting anything, or rolling over. the tire was inflated to manufacturer's recommendations, and i had hit nothing that would have caused the tread separation. i had stopped for fuel about 20 minutes earlier, and the tires looked normal at that time. i was not hauling a load, or pulling a trailer at the time. in roughly a million miles or driving i have never had a tire fail like this, and don't ever want another failure like it. i have always had some sort of warning of an incipient failure. the tires were on the truck when i bought it about one and one-half years ago, so i don't know where they were purchased. i had the truck aligned twice, and the tires rotated as part of normal maintenance. the separated tread caused about $4000 damage to my vehicle. i have contacted sigma product liability and filed a report with them.

Reported in: BRISTOL TN || Crash: N || VIN #:

WHEELS

almost went off road on a corner, with only 53,000 miles on it. took it into lesscwabs and they said the wheel bearings and hubs were shot and the wheel was ready to fall off. they said that they have had several chevy silverados with the same problem with even less mileage on. called chevy they said they have also had several complaints but there is no recall or help with fixing the problem. it cost aprox 900.00. to fix @ schawbs.

Reported in: WALTON OR || Crash: N || VIN #: 1GCHK29U74E

SUSPENSION

Reported in: WALTON OR || Crash: N || VIN #: 1GCHK29U74E

SERVICE BRAKES, HYDRAULIC

rusty rotors.

Reported in: JULIAN NC || Crash: N || VIN #:

ELECTRICAL SYSTEM

wipers will not turn off. have to pull fuse to get wipers to turn off. i cannot re-install the fuse unless i stop and get out of the vehicle to do this. if i do not pull the fuse, the wipers will eventually start to damage the windshield. i have read multiple incidents of this online, with no definite fix. truck has 68,000 miles on it.

Reported in: SAPULPA OK || Crash: N || VIN #:

VISIBILITY

Reported in: SAPULPA OK || Crash: N || VIN #:

ELECTRICAL SYSTEM: INSTRUMENT PANEL

we have a 2004 chevy silverado 2500hd. we bought the vehicle with 45k miles on it. not long after, the speedometer started acting up. i turned the truck off, restarted and the speedometer was fine. we now have 100k miles on the truck and the speedometer reads 120mph all the time. this has clearly been a huge problem with chevy, but yet they aren't taking responsibility for the problem. the dealerships continue to make $500-$800 on each incident. we've called multiple dealerships and not one of them will cover it.

Reported in: ELLSWORTH WI || Crash: N || VIN #:

ELECTRICAL SYSTEM: INSTRUMENT PANEL

tl* the contact owns a 2004 chevrolet silverado 2500 hd. the contact started the ignition and observed that the speedometer displayed an inaccurate reading of 100 mph. the speedometer reading fluctuated at any speed being traveled. the vehicle was taken to an authorized dealer where the technician stated the service repair would be an estimated cost of $800.00. the vehicle had not been repaired at the time of the complaint. the failure mileage was 118,700.

Reported in: MONROE NC || Crash: N || VIN #: 1GCHK29264E

SERVICE BRAKES, HYDRAULIC

tl*the contact owns a 2004 chevrolet silverado 2500 hd. while the emergency brakes was engaged, the brake pedal extended to the floor. the contact took his vehicle into the dealer and the rotors were turned; however, the failure recurred. the dealer used sand paper on the rotors. the failure has continued to occur. the failure mileage was 11,000 and the current mileage was 19,365.

Reported in: HUBBARD LAKE MI || Crash: N || VIN #: 1GCHC24U14E

SERVICE BRAKES, HYDRAULIC:ANTILOCK:WHEEL SPEED SENSOR

tl* the contact owns a 2004 chevrolet silverado 2500 hd. the contact was driving at approximately between 5-10 mph coming to a complete stop. when the brakes were engaged an unintended activation of the anti-lock brake system occurred which required an increase in the stopping distance. the failure occurred intermittent at low speeds which had progressed. the contact inspected the vehicle and detected corrosion on the front wheel speed sensor. there was a safety related recall on the model years 1999-2000 chevrolet silverado 2500 hd. the vehicle had not been repaired at the time of the complaint. the failure mileage was 23,000.

Reported in: WARE MA || Crash: N || VIN #: 1GCHK29U34E

EQUIPMENT

gm, you have got to be kidding me!!!! if i was on the side of the highway with my boat on the back, i'd have unhitched the boat, moved it to a safe location, and then torched the truck to the ground! ok not really, but i'm just beside myself that gm would do such a dumb move and install a safety feature which would hinder you in an emergency situation. my 2004 silverado has a "safety latch mechanism" for the spare tire that becomes rusted or dirty and won't allow you to get the tire down!! they should at least warn people to check it and see if it will lower and to grease it or put anti-seizing compound on it, something. the dumb thing says patent pending on it! what a joke! they need a better design and recall! i've heard of people having them burnt off to get it down! that is what the dealership told me they would do for about $225 - crazy! read this and more from other drivers on the internet!!!! the winch part number is 15247311. the part costs around $100. there is definitely a corrosion issue with the secondary latch. best to check it, clean it, grease it, when checking air pressure on the spare. spare tire will likely drop a couple inches when you uncrank the winch. if it hangs up at that point, the secondary latch is not releasing. continuing to uncrank the cable can tear up the winch, as the cable has nowhere to go. after lowering the tire a couple inches, try supporting the tire and forcing it back up. this may give you enough room to fuss with the crusty secondary latch mechanism without having the tire drop on you. you may be able to free it up and then further lower it to clean and grease it. if anyone from gm reads this, you should not be proud of this latch. anyone from detroit should recognize that the underside of the car is a corrosive environment and that should have been considered in this design. the tightly fitting parts and tiny spring can not withstand the exposure to dirt, water, salt, etc... and it turns to junk very quickly. updated 08/24/10. *lj updated ivoq 08/25/10*jb

Reported in: CHINA TWP. MI || Crash: N || VIN #: 1GCHK29U04E

ELECTRICAL SYSTEM

under normal driving conditions the hvac system switches from cooling fine to full heat mode. the hvac compressor is still running, however some type of damper servo malfunctions to let in hot air (poss from the heater core area) opens full and replaces the cold air with extremely hot air. it happens about every 7-10 miles on a bad day and once a day on a good day. the only remedy i have found for it is to pull over to the side of the road, place the vehicle in park, turn off the ignition, open the door to kill the interior power, close the door, restart the vehicle. this some how resets the damper servo to its proper operating range.

Reported in: MIAMI FL || Crash: N || VIN #: 1GCHK23274F

VISIBILITY:DEFROSTER/DEFOGGER SYSTEM

Reported in: MIAMI FL || Crash: N || VIN #: 1GCHK23274F

STEERING

the intermediate steering shaft becomes worn or loose resulting in severe vibrations and noise when driving at moderate speeds and when turning. the vibrations result in a loss of precise steering control. the intermediate steering shaft has been replaced twice by the dealer. the problem recurs several thousand mile after the shaft replacement. the manufacturer knows this is a widespread problem but has not implemented a permanent fix.

Reported in: BONITA SPRINGS FL || Crash: N || VIN #: 1GCHK23U24F

FUEL SYSTEM, DIESEL

2004 chevy 2500 hd truck with 6.6 duramax diesel lose fuel suction. must manually pump up fuel system to get truck started.

Reported in: NILAND CA || Crash: N || VIN #:

SERVICE BRAKES, HYDRAULIC

severely rusted brake lines. they did not bust yet, but are so deteriorated after only 12,000 miles, i'm afraid to drive it. the manufacturer needs to replace these line with lines of a better material.

Reported in: HAZLETON PA || Crash: N || VIN #: 1GCHK24U54E

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS

tl*the contact owns a 2004 chevrolet silverado 2500 hd. the contact stated that he experienced increased stopping distance when braking at any speed. the vehicle was taken to an authorized dealer where the contact was informed that the vehicle was leaking brake fluid. the vehicle was repaired at that time. the failure occurred three times after the repair and the vehicle was taken back to the dealer. while driving approximately 25 mph, the contact applied pressure to the brake pedal which extended to the floorboard. he applied the emergency brake and the vehicle rolled to a stop. the vehicle was towed to an authorized dealer where the contact was informed that the brake lines were corroded. the vehicle was repaired. the failure had not occurred since the repair. the failure mileage was 51,222 and the current mileage was approximately 83,000. updated 12/29/10 *bf also, the hydro brake booster was leaking. updated 04/06/11

Reported in: SAG HARBOR NY || Crash: N || VIN #: 1GCHK29U74E

ELECTRICAL SYSTEM: INSTRUMENT PANEL

2004 chevy silverado - the speedometer is not showing the correct speed. my son who just received his permit was driving with me in the passenger seat when we were pulled over by a policeman for doing 20 miles over the speed limit. i was so surprised, i constantly check his speed on a regular basis when he is driving and would never have allowed this to occur. after a nasty ticket. i went home and researched that there is a recall on this vehicle for the dash cluster not working properly. i sent the truck to a neighborhood auto repair shop who ran it on their dynometer and found that the speedometer was grossly off. i contacted chevrolet and they will not honor the recall because the vehicle has 112,000 miles on it. i purchased the vehicle from enterprise leasing company 1 year ago when it had 101,000 miles on it. so i went to them for recourse and they too will not honor the recall because it has too many miles on it. i am appalled that this was not taken care of before i unsuspectingly bought the vehicle from a reputable company that should have made sure that it was in good working order before they sold it. at the very least no outstanding recalls. now i'm stuck with a speeding ticket cost and the new dash cluster.

Reported in: WALLINGFORD PA || Crash: N || VIN #: 1GCHK29244E

ELECTRICAL SYSTEM

2004 chevy silverado 2500hd instrument panel full failure while vehicle is in motion causing loss of all instrument readouts.

Reported in: CHESTERFIELD VA || Crash: N || VIN #: 1GCHK29194E

ELECTRICAL SYSTEM

heater fan wiring harness overheats burns thru at connector between resistor and harness. several wires in connector -the lead for full power to motor ( high speed setting) is supplied by 40 amp fuse. wire is approx 16 gage with terminal connections subjected to long duty cycle with high amp load. wire harness overheated causing fire in vehicle in oct 2005 ( 7,657 miles). repaired under warranty. repeat failure in aug 2010 ( 24,615 miles) on 2nd failure dealer stated happens all the time so he had parts dept keep ample supply of resistors and harnesses in inventory. refused to repair under warranty. 2nd repair done by vehicle owner. part numbers used in 1st repair by dealership were; connector 88953358 and resistor 89018596. 2nd repair by vehicle owner used delco parts #s - connector del15-81086, and resistor del pt2485. on 2nd repeat failure the new connector appeared more robust in design in area of contact patch between harness and resistor. terminal interface seemed improved.

Reported in: HOLLEY NY || Crash: N || VIN #: 1GCHK29234E

ELECTRICAL SYSTEM: INSTRUMENT PANEL

tl*the contact owns a 2004 chevrolet silverado 2500 hd. while driving approximately 45-55 mph he noticed that the speedometer was no longer working and displayed zero. the vehicle was taken to a local mechanic and was being serviced when the complaint was filed. the manufacturer was called and advised the contact that they were unable to assist with the repair cost. the failure mileage was unknown. the current mileage was approximately 145,000. updated 01/28/11*lj updated 02/14/11

Reported in: FRIENDSHIP MD || Crash: N || VIN #: 1GCHK23104F

SERVICE BRAKES, HYDRAULIC

brake line rusted - lost all braking suddenly due to loss of brake fluid had vehicle towed to repair shop - fixed.

Reported in: LAUGHLINTOWN PA || Crash: N || VIN #:

ELECTRICAL SYSTEM

tl*the contact owns a 2004 chevrolet silverado 2500 hd. while driving at any speed, the contact stated that the speedometer would display the correct speed and then it remained at the same speed regardless of how fast or slow she was driving. the failure began three months ago. the dealer and the manufacturer were notified and advised her that there were no related recalls. the contact did not take the vehicle to the dealer for diagnostic testing due to the cost. the vehicle was not repaired. the current mileage was approximately 96,000. the failure mileage was approximately 85,000.

Reported in: CLOVIS NM || Crash: N || VIN #: 1GCHK23U74F

SERVICE BRAKES, HYDRAULIC

i was driving on city street at stepped on the brakes to stop at a light. brake pedal had more travel than normal. drove truck home and brakes were becoming increasingly less effective. upon inspection at home, found brake fluid dripping from under the truck. truck was towed to shop. shop found that brake lines to rear of truck had corroded through and needed replacement. shop said they had fixed at least 15 similar trucks this year with same problem.

Reported in: LABADIE MO || Crash: N || VIN #: 1GCHK23174F

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

brocken exhaust manifold bolts.

Reported in: EVANS CITY PA || Crash: N || VIN #: 1GCHK29U54E

SERVICE BRAKES, HYDRAULIC

tl*the contact owns a 2004 chevrolet silverado 2500 hd. the contact stated that while decelerating, he noticed his brakes weakening as he would slow down. he then pulled over to examine the vehicle where he noticed a leak in the brake line and that it was covered with rust. the vehicle was not repaired. the failure mileage was approximately 102,000.

Reported in: IRVINGTON AL || Crash: N || VIN #: 1GCHC23214F

ELECTRICAL SYSTEM

tl*the contact owns a 2004 chevrolet silverado 2500 hd. the contact stated that the heater electrical resistor, and connectors melted causing the heater blower to fail. the vehicle was taken to the dealer who replaced the connectors, and resistors. the manufacturer was contacted, but they will not assist with the repair. the failure mileage was 80,000 and the current mileage was 85,500.

Reported in: LAMBERTVILLE MI || Crash: N || VIN #: 1GCHK29224E

STRUCTURE:BODY:HOOD:HINGE AND ATTACHMENTS

tl* the contact owns a 2004 chevrolet silverado 2500 hd. the contact stated that while the vehicle engine compartment was being inspected at the local repair shop, the hood of the car came down abruptly on the mechanics head and neck. the mechanic sustained some bruises on the back of his neck and head. the failure and current mileage was 194,399.

Reported in: JACKSONVILLE FL || Crash: N || VIN #: 1GBHK24U14E

WHEELS

tl* the contact owns a 2004 chevrolet silverado 2500 hd. the contact stated that four of the eight studs and lug nuts that held the tires and wheels were missing from the front passenger side. the manufacturer was contacted and informed him there are no recalls and he would have to pay for any repairs. the dealer was contacted by the manufacturer who informed the contact to bring the vehicle in for them to run a diagnostic test but at a cost to the contact. the vehicle was not repaired. the failure mileage was 61,000.

Reported in: LAREDO TX || Crash: N || VIN #: 1GCHK23134F

SERVICE BRAKES, HYDRAULIC

tl*the contact owns 2004 chevrolet silverado 2500 hd. the contact stated that while driving, she depressed the brake pedal which suddenly extended to the floorboard. she was able to stop the vehicle by using the gears. the vehicle was taken to a local mechanic who stated that the brake lines were rusted and leaking. the vehicle was not repaired. the manufacturer was notified but offered no assistance. the failure and current mileages were 69,000.

Reported in: FINCASTLE VA || Crash: N || VIN #: 1GCHK23G74F

SERVICE BRAKES, HYDRAULIC

tl* the contact owns a 2004 chevrolet silverado 2500 hd. the contact stated that while driving approximately 30 mph and attempting to decelerate, the brakes failed without warning. the contact was able to drift to a stop on the side of the roadway. the vehicle was towed to a dealer who informed the contact that the brake line was severely rusted and would need to be replaced. the vehicle was not repaired. the failure mileage was approximately 75,000.

Reported in: CAILFON NJ || Crash: N || VIN #: 1GCHK24U74E

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS

tl* the contact owns a 2004 chevrolet silverado 2500 hd pickup. the contact was reversing 5 mph in a residential driveway. he then applied the brakes and the brake pedal went into the floorboard abnormally. the contact stated that there was a large amount of brake fluid leaking from the vehicle and onto the concrete. the vehicle was towed to a local repair shop where the contact was advised that the brake lines would need replacing because they had rusted. the manufacturer was contacted but provided no assistance. the vehicle was not yet repaired. the failure mileage was 120,000.

Reported in: NORTH FORT MYERS FL || Crash: N || VIN #: 1GCHK292X4E

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS

2004 chevrolet silverado 2500 hd. consumer states brake failure while driving *tgw the consumer stated in order to stop the vehicle, she/he had to push the brake pedal to the floor, gear down and use the trailer gear . the gear was then placed in park when the consumer reached a stop light, in case the vehicle lunged forward. the consumer left the vehicle at his/her mechanic to be inspected the next day. the mechanic informed the consumer that all the brake lines had rusted and were leaking in some areas. *jb

Reported in: FINCASTLE VA || Crash: N || VIN #: 1GCHK23G74F

SERVICE BRAKES, HYDRAULIC

truck: 2004 chevrolet silverado 2500hd, 6.6l diesel. location: upstate ny problem: while testing the brakes before towing a trailer, the pedal pushed completely to the floor and brake fluid poured to the ground from under the drivers side door. upon inspection of the brake lines, it showed one of the lines on the frame rail had severe corrosion and had burst. all of the brake fluid drained out of the master cylinder through this broken line. i checked the operation of the brakes after the broken line to see if i had any ability to stop the vehicle. this was not the case as the brakes would not even stop the vehicle from moving at an idle. if this had occurred at operating speeds, especially while towing, i would have not been able to stop the vehicle. currently the truck is at a repair facility to have the lines replaced and system checked.

Reported in: WEST WINFIELD NY || Crash: N || VIN #:

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

recently i developed an exhaust leak near the front of the exhaust system near the engine. upon inspection i found the back manifold bolt had been broken off on the drivers side (i may also have a broken bolt on the passenger side as well). i took the vehicle to my locally respected mechanic with the intention of having the broken bolt removed and a new one installed. i was notified that this was a common problem with these gm vehicles (2004 silverado 2500hd). i was further informed that there was no way the repair would be simple due to the fact there was no practical manner in which to extract/drill out the broken bolt for replacement. i was told the head would need to be removed in order to effect the required repair which would cost somewhere between $700-$1000. this repair is not cost effective to me for what is probably a $3.00 bolt. researching this issue on the internet i found out it is in fact a problem with these vehicles dating back to 1999. why has gm not been required to repair this item at no cost to the owner if it is this widespread.

Reported in: SPANAWAY WA || Crash: N || VIN #: 1GCHK23U04F

ELECTRICAL SYSTEM

instrument panel cluster has started providing inaccurate readings including erratic speed display. problem started at 86,000 miles. chevrolet will not cover replacement as over the mileage limit.

Reported in: BLAINE MN || Crash: N || VIN #: 1GCHK23U64F

ELECTRICAL SYSTEM

82000 miles, speedometer cluster stopped working. gauge shows 75-120mph at all times. it is unknown exactly how fast the vehicle is travelling at any given time.

Reported in: BEMIDJI MN || Crash: N || VIN #: 1GCHK23U14F

SERVICE BRAKES, HYDRAULIC

when coming to a stop sign with my 2004 chevy pickup the brake pedal went to the floor, but i was able to stop. after getting out i saw brake fluid coming down at about the drivers door along the frame. i took it to a garage to be repaired and was told that i need new brake lines. especially the ones from the master cylinder and the front brakes to the abs controller. were these lines meet the frame there is a plastic clip and at that point the lines were rotted. at this time all the brake lines need to be replaced. also in the pass i had to replace all the rotors on the truck because they were rotten. this is the first time i ever seen a rotor that was rotten.

Reported in: BEACON FALLS CT || Crash: N || VIN #: 1GCHK29144E

SERVICE BRAKES, HYDRAULIC

Reported in: BEACON FALLS CT || Crash: N || VIN #: 1GCHK29144E

ELECTRICAL SYSTEM: INSTRUMENT PANEL

i was just driving my yukon and the speedometer was reading 100 miles i knew something was wrong because when i stop and turn it off the speedometer stayed at 40 miles and i don't know at what speed am at when am on the freeway, i as a mechanic shop an they told me that i had to go to the dealer for that.

Reported in: VANCOUVER WA || Crash: N || VIN #: 1GCHK29U94E

SERVICE BRAKES, HYDRAULIC

a brake line burst during testing after the master cylinder failed and was replaced. the tech said all lines were badly corroded and need to be replaced. the master cylinder failed in heavy traffic at freeway speed and would have caused a serious accident if weren't for the brakes on the trailer i was pulling.

Reported in: IRON RIVER MI || Crash: N || VIN #: 1GCHK29UX4E

SERVICE BRAKES, HYDRAULIC

Reported in: IRON RIVER MI || Crash: N || VIN #: 1GCHK29UX4E

ELECTRICAL SYSTEM

i recently purchased in chevy 2500 hd silverado from an individual and the gauges on the dash are not working properly. luckily, the person i bought it from was honest enough to let me know this before i test drove the truck. he told he had already spoke to the local chevy dealer and they said it was a common problem and it could be repaired under warranty if the vehicle had under 75,000 miles.the truck had 142,xxx when i got it. i talked to another mechanic and he also verified that this is a common problem with these trucks, as is a hole being eaten up in the transfer case of the 4x4. the repair estimate i got is $350. i think a class action lawsuit should be filed on behalf of all the current owners( or persons that had to pay for this repair) against gm. i am unable to monitor my speed, temp, oil pressure, voltage, fuel or trans temp accurately because of this. if the motor were to burn up due to overheating, i would have no way of knowing it until it was too late. if anyone knows of a lawyer willing to take on a case such as this, i will be more than willing to sign my name due to the fact i am having to pay for the repair to avoid more serious damage to the vehicle or a possible of life if the vehicle were to catch fire from overheating. information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6).

Reported in: ECHO LA || Crash: N || VIN #:

ELECTRICAL SYSTEM

insturment panel making noise and malfunctioning. happened since about 40,000 miles on truck. then a few days ago smoke was coming from dash. shut truck off and disconnected battery. called the dealer and they said warranty had just expired in january. called gm they said to take it to a dealer for a diagnostic test and they would see if the would "possibly help" with the cost of repairs.

Reported in: WALTON OR || Crash: N || VIN #: 1GCHK29U74E

SERVICE BRAKES, HYDRAULIC

while driving home from the gas station my brake pedal went to the floor and i lost my brakes, i had the truck towed home only to find out that the brake lines were leaking brake fluid. the lines were so rusted that they had holes and had fallen apart. i had to have all the brake lines replaced from front to back on the entire truck, the truck was completely unsafe due to all the brake lines being so rusted, my truck is primarily used to pull my 5th wheel camper. that day i had filled up with gas to leave the next morning for a camping trip. i thank god that my family was not in the truck and no one got hurt. when i lost my brakes on april 8, 2011 i was fortunate enough to be able to get to the side of the road without hitting anyone or anything thing, i was doing about 40 mph and had to pull the emergency brake to help slow me down and stop. it was a frightful experience. my truck only has 54,350 miles on it and is very well maintained. replacing all the brakes lines has been very expensive. i now am concerned about the fuel lines which do not look much better.

Reported in: CENTRAL ISLIP NY || Crash: N || VIN #:

AIR BAGS

tl* the contact owns a 2004 chevrolet silverado 2500 hd. the contact stated that as the vehicle was started, the front driver side air bag inadvertently deployed. the contact suffered minor injuries from the air bag deployment. the vehicle was taken to an authorized dealer where it was in the process of being repaired. the failure and current mileage was 61,900. updated 05/24/11*lj updated 05/26/11*jb

Reported in: SNOHOMISH WA || Crash: N || VIN #: 1GCHK29U84E

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

the exhaust manifold bolts are broken on my 2004 chevrolet 2500 hd truck. they are also broken on my sons 2004 gmc 2500 hd and my brothers 2005 gmc 2500hd. something is wrong with that and something should be done before they catch fire.

Reported in: DOUGLAS MA || Crash: N || VIN #: 1GCHK29U04E

ELECTRICAL SYSTEM: INSTRUMENT PANEL

complete failure of the dash clusters, no oil pressure reading, no speedometer reading that could result in tickets or accidents.

Reported in: RIVERSIDE CA || Crash: N || VIN #:

SERVICE BRAKES, HYDRAULIC

tl* the contact owns a 2004 chevrolet silverado 2500 hd. while driving approximately 40 mph, the contact applied the brakes repeatedly and there was no response. the vehicle failed to slow down and crashed into a preceding vehicle. the rear passenger sustained a minor injury to the neck. in addition, the other vehicle driver suffered a neck injury. a police report was filed. the vehicle was towed to an independent mechanic for repairs. the approximate failure mileage was 130,000.

Reported in: LOWMAN NY || Crash: Y || VIN #: 1GCGK29U6YE

SERVICE BRAKES, HYDRAULIC

no accident yet - wheel is rubbing brake hose. factory wheel, factory brake hose. no aftermarket parts involved. left front rubber brake hose.

Reported in: GREENVILLE PA || Crash: N || VIN #:

ELECTRICAL SYSTEM

notice sent out after my vehicle exceeded warranty,instrument cluster failure,7yrs or 70,000 miles ,letter sent out nov 2007,80000plus on my chevy truck at time of recall,gm still having problems instrument cluster,now they want $500-$650.00 to repair what a joke,last chevy vehicle i purchase!!!!!!!

Reported in: KENNEWICK WA || Crash: N || VIN #: 1GCHK23154F

SERVICE BRAKES, HYDRAULIC

brake line burst and we lost our brakes! slow speed and rural location so we were able to stop by steering off-road and into some bushes. inspected the brake lines and found a leak in the steel line going to the left front brake. the brake line had extensive corrosion on it as well as corrosion on adjacent lines. this is not a maintenance issue, steel brake lines in this part of the country do not rust out at 67,606 miles... except on this truck. shameful design and poor materials are the cause. somebody could have been injured or killed!

Reported in: NORWICH VT || Crash: Y || VIN #: 1GCHK24U04E

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

i own a 2004 chevrolet silverado 2500. it has a broken exhaust manifold bolt. after researching this problem on the internet, i found there are approximately 12,000,000 gm vehicles with this problem. why hasn't the nhtsa issued a recall on these vehicles? it seems to me that the epa would have done something about as the broken bolt is allowing exhaust into the air without going through the converter. i don't know at what mileage the bolt broke or at what speed i was going when it happened.

Reported in: CONCORD NH || Crash: N || VIN #: 1GCHK29G64E

SUSPENSION:REAR

tl* the contact owns 2004 chevrolet 2500 hd.the contact stated that the rear axle shock mount fractured. the vehicle was taken to an independent mechanic where the mechanic attempted to order the part from the manufacturer. the manufacturer advised that the entire axle would need to be purchased and replaced because the part was not sold separately. the vehicle was not repaired. the approximate failure mileage was 54,000.

Reported in: ESSEX MA || Crash: N || VIN #: 1GCHK29U84E

ELECTRICAL SYSTEM: INSTRUMENT PANEL

the gauge cluster, including speedometer, failed at 70,000 miles. nhtsa has received numerous complaints about this model. general motors will not replace the gauge cluster after the warranty expires, even though this is clearly a design problem as evidenced by the thousands of complaints. *kb

Reported in: CENTRAL POINT OR || Crash: N || VIN #:

SERVICE BRAKES, HYDRAULIC:FLUID

i was on a state road doing 50 mph leaving my town and went to turn and my brake pedal went to the floor. i was able to slow down and pull over and not get in an accident. i was able to get home and discovered no brake fluid. i filled up the fluid and started to bleed the brake. that's when i noticed the rusted out brake lines and the brake fluid spraying out. i have ordered new brake line from inline tube. i was lucky to not crash but i am worried about others who may have this problem and not be as lucky as me. *kb

Reported in: CHESTERTOWN MD || Crash: N || VIN #: 1GCHK29U94E

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS

Reported in: CHESTERTOWN MD || Crash: N || VIN #: 1GCHK29U94E

SERVICE BRAKES, HYDRAULIC

Reported in: CHESTERTOWN MD || Crash: N || VIN #: 1GCHK29U94E

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS

i own a 2004 silverado 2500hd crew cab. i was leaving a lake boat ramp with my boat in tow when, without warning, the brake pedal went to the floor. with the assistance of the e-brake i was able to bring it to a stop on the shoulder. after inspecting under the hood i went under the truck and found that the brake lines into the proportioning valve were severely rusted and one had ruptured. i had to have the vehicle towed at this point. upon returning home i began looking for replacement parts and found that your agency is investigating this problem. i find it unsatisfactory that there hasn't been at least an advisory to at least inspect so at least the owners of these vehicles would have a chance to protect themselves, their property, and other individuals from harm. thank goodness i was not going any faster than i was. there was no warning and i had my family with me. would you please at least put something out. i know there is currently no recall. how can this be??? there is nothing more dangerous than a 9000lb+ truck with no brakes!! how long do you plan on "researching" this? i am an aircraft mechanic and know that safety changes are usually written in blood!! please stop acting like the faa and be proactive on this issue. updated 08/11/11 *bf updated 06/06/12* js

Reported in: NEWNAN GA || Crash: N || VIN #: 1GCHK23UX4F

SERVICE BRAKES, HYDRAULIC

i was backing truck into drive way moving about 5mph and applied brakes to put truck into reverse and brake pedal went to floor did not stop truck. steel brake line ruptured where the abs module is under the truck right below driver seat. all brake lines look extremely rusty. truck is a 2004 2500hd crew cab 4x4. i bought brand new and it has 47,212 miles. i pull a 7000 lbs. camper and i'm glad it happened in my driveway. in june the rubber gas line failed pumping 15 gallons of gas onto bottom of truck and ground on the way to work (27 miles). once again, i was lucky. i prefer to not have any other strikes, two is enough for me! i hope it does not take an injury, death, accident or property damage to get the needed attention this vehicle needs.

Reported in: OHIO OH || Crash: N || VIN #: 1GCHK23U04F

FUEL SYSTEM, GASOLINE

Reported in: OHIO OH || Crash: N || VIN #: 1GCHK23U04F

ENGINE AND ENGINE COOLING:ENGINE

tl* the contact owns a 2004 chevrolet silverado 2500 hd diesel. the contact stated while driving, the check engine light illuminated and the vehicle stalled. the contact mentioned the failure happened several times. the vehicle was taken to the dealer who was unable to diagnose the failure. the manufacturer was made aware of the failure but stated they would contact him at a later date. the vehicle was not repaired. the failure mileage was unknown and the current mileage was 124,869.

Reported in: SPOKANE WA || Crash: N || VIN #: 1GBHK29204E

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:MANIFOLD/HEADER/MUFFLER/TAIL PIPE

2004 chevrolet silverado 2500hd. consumer states gauges stopped working and the bolts on the manifold were defective. *tgw

Reported in: WASHINGTON DC || Crash: N || VIN #:

ELECTRICAL SYSTEM: INSTRUMENT PANEL

2004 chevrolet silverado 2500hd. consumer states gauges stopped working and the bolts on the manifold were defective. *tgw

Reported in: WASHINGTON DC || Crash: N || VIN #:

ENGINE AND ENGINE COOLING:ENGINE

air cond. compressor failed, seized!. *kb

Reported in: BROADALBIN NY || Crash: N || VIN #: 1GCHK29U84E

SERVICE BRAKES, HYDRAULIC

2004 silverado 2500 hd, while towing approx. 7000lbs my brake line ruptured, luckily i had the trailer brakes to stop me because the pedal went straight to the floor. upon inspecting closely the brake lines are so rusted you can literally smash them between your fingers. this is the newest vehicle i own and is in the worst shape as far as corrosion goes, a shame at 70k miles. truck is in the shop now, can only imagine what this will cost. already replaced rotors due to corrosion, e-brake cables, wheel speed sensor(bracket rotted off). *kb

Reported in: ACME PA || Crash: N || VIN #: 1GCHK24U44E

PARKING BRAKE:DRIVELINE:HYDRAULIC:HOSES, LINES/PIPING, AND FITTINGS

Reported in: ACME PA || Crash: N || VIN #: 1GCHK24U44E

ENGINE AND ENGINE COOLING

i have a 2004 silverado k2500 with a duramax diesel (lly). i bought this truck new in september 2004. i pull a fifth wheel camper. my truck has overheated more than two dozen times, and on some occasions lost power, while pulling the camper up long grades. i reported this problem twice to chevrolet dealers. i have the service orders that clearly describe my overheating problem. both of these service calls were while the truck was under warranty, but the dealers could not fix the problem. later when the truck was out of warranty, i found out that general motors recognized the overheating problem and issued a service bulletin #06-06-04-036d that describes my heating problem exactly. this service bulletin was issued prior to either of my complaints about overheating. the cost of implementing service bulletin #06-06-04-036d is approximately $1,300 dollars, so general motors recognizes that this series truck has a significant overheating problem, but apparently they are hiding this fix from the owners until the vehicle is out of warranty. i can give many instances where this overheating problem has caused a safety problem. one time i was pulling the camper east on interstate 40 about a 150 miles west of albuquerque, nm when the truck overheated and lost power. there was no good place to pull over and i was terrified as the heavy traffic had to change lanes and pass me. another time i was pulling up to the north rim of the grand canyon on a two lane road when the truck overheated, lost power and i had a long line of traffic behind me. it was dangerous as the traffic passed me without good clearance. i could go on and on of similar situations that caused dangerous conditions. there is also a website at www.dieselplace.com that has an entire section devoted to the lly diesel. there are over a thousand posts concerning this overheating problem.

Reported in: PIKETON OH || Crash: N || VIN #: 1GCHK29224E

ELECTRICAL SYSTEM

2004 chevrolet silverado. fire investigator writes in regards to vehicle dash fire *tgw the vehicle was heavily damaged by a fire which reportedly originated in the dash. the fire spread and consequently consumed the passenger compartment, then spread to the engine. the problem manifested while the driver was using the cigarette lighter. prior to the fire, the transmission, alternator and a 15 amp fuse lighter fuse was replaced. the cigarette lighter was used frequently, plugging a 400 watt inverter which allowed the driver to use his computer. at the time of the fire, the consumer was driving on the highway when he unplugged the inverter from the cigarette lighter socket and inserted his cigarette lighter which popped back. about a second later, white smoke starting coming from the dash. there were no cigarettes in the ash tray. the smoke started to increase and the consumer identified the problem as an electrical insulation smoke odor. the smoke was coming from the back of the dash; there was no smoke coming from the engine compartment or the hood at that time. it was in the fire investigator's opinion, that the results of the examination lead to a conclusion that on a more probable than not basis, an electrical anomaly at the dash area and in the vicinity of the cigarette lighter ignited nearby combustibles and the fire spread into the passenger compartment. (letter sent in by fire investigator) *jb

Reported in: GRANTS PASS OR || Crash: N || VIN #: 1GBHC24U54E

POWER TRAIN

Reported in: GRANTS PASS OR || Crash: N || VIN #: 1GBHC24U54E

ENGINE AND ENGINE COOLING

tl* the contact owns a 2004 chevrolet silverado 2500 hd. the contact stated that while towing a trailer at approximately 55 mph, a clicking noise was heard from the engine and the engine exploded. the contact also observed smoke rising from the engine during the failure. the vehicle was towed to an independent repair shop where the contact was informed that the engine exploded and all of its components were melted. the vehicle was then towed to an authorized dealer where the failure was confirmed and the contact was advised that the engine was destroyed. the vehicle was repaired. the manufacturer was made aware of the failure, but offered no assistance. the failure mileage was 55,000.

Reported in: LAKE CITY FL || Crash: N || VIN #: 1GCHK29114E

SERVICE BRAKES, HYDRAULIC

total brake failure in my driveway. brake lines rusted through. *kb

Reported in: FAIRLAWN OH || Crash: N || VIN #: 1GCHK29GX4E

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS

total brake failure in my driveway. brake lines rusted through. *kb

Reported in: FAIRLAWN OH || Crash: N || VIN #: 1GCHK29GX4E

SERVICE BRAKES, HYDRAULIC

was testing the brakes on a boat trailer before towing it away and a steel brake line running inside the frame channel behind the driver's side rear wheel suddenly burst. upon inspection, the line was completely rotten for about a 3 to 4 inch section in that area. no warning, another 10 minutes i would have been towing a heavy trailer and the brakes would have failed at any sudden stop. after this line failure, the truck has no brakes except the e-brake, which isn't much. hopefully there will be a recall, though i already dropped $600 at the shop to get it fixed today.

Reported in: NORTHVALE NJ || Crash: N || VIN #: 1GCHK29G44E

SERVICE BRAKES, HYDRAULIC

not only have i had problems with the emergency brake sticking and rear brakes but the brakes and fuel lines where it makes a turn around the frame just under the driver side foot well are scary rusted as if they used a cheap steel for the lines. i was a chevy dealer mechanic in the 1980s and know what im looking at. i havent had the lines blow out yet but im sure they will. also all the gauges in the instrument cluster exept the odometer and gas gauge and the fan controls do not work. *tt

Reported in: CRESSKILL NJ || Crash: N || VIN #: 1GCHK24U84E

SUSPENSION

we had a life threatening event on october 19, 2011. the left lower control arm was broken and the right lower control arm was cracked ready to break. this was discovered when we went for a wheel alignment. we had to have them repair it immediately due to the danger of the problem. the pitman arm and idler arm needed to be replaced because of this problem. we don't have a chevrolet dealership here. they said the lower control arms were defective. we use this truck only for pleasure, no hauling. we e-mailed the chevrolet consumer support center and they gave us a service request number. we were requested by them to communicate by phone. we called them on october 21, 2011 and they requested the alignment shop's phone number. on october 25, 2011, they called us and said that this was not under warranty. they didn't seemed to be concerned that the parts were defective. we wanted to let you know of this dangerous problem since there may be more defective lower control arms. i still have the defective parts.

Reported in: YUCCA VALLEY CA || Crash: N || VIN #: 1GCHC231X4F

SERVICE BRAKES, HYDRAULIC

2004 chevrolet silverado 2500hd lt 4x4 extended cab short bed all hard steel brake lines are severely rusted. i was told by the dealer 2 days ago that my general motors warranty (it is a gm warranty purchased though the gm dealer not some other company) does not cover rust on any parts. in order for them to be replaced they must fail. i sorry but brake lines failing with my wife and 6 month old daughter in the truck is not acceptable to me. please help us get gm to recall these vehicles and replace the lines with all stainless steel lines. thanks for your help in this matter.

Reported in: WATERBURY CT || Crash: N || VIN #:

SERVICE BRAKES, HYDRAULIC

the brake lines ruptured during a panic stop and required the emergency brake to bring the truck to a stop. the truck was towed to a service center that found that all the brake lines are severely rusted.

Reported in: MURRYSVILLE PA || Crash: N || VIN #: 1GCHK23U74F

SERVICE BRAKES, HYDRAULIC

failure of corroded brake lines.

Reported in: SAUGERTIES NY || Crash: N || VIN #: 1GCHK29U44E

SERVICE BRAKES, HYDRAULIC

went to use the truck and brake pedal went to the floorboard. looked under the truck and fluid had shot out everywhere. two blown brake lines due to rotted out condition of the lines. repair total of $411.68. 2 lines plus fittings plus new bleeder screws. the mechanic tells me this is a common problem with gm pick-ups and that the other brake lines are on the edge of going also. these lines too are rotted and need to be replaced asap. i see that there is an investigation with the nhtsa action number of ea11001. the investigation should be expanded to include additional years for vehicles before 1999 and after 2003. i was lucky my incident happened in the driveway and not doing 70 mph out on the highway. i am looking at an additional repair bill of about $750-$800 to replace the other lines. needless to say i am distressed to be in this position due to the materials used and installation position of these lines. *kb

Reported in: HOLDEN MA || Crash: N || VIN #: 1GCHK24U84E

FUEL SYSTEM, GASOLINE

i had my fuel injectors replaced in june of 2010 under an extended warranty from gm with no out of pocket cost. 18 months later i am having the same problem, fuel injector failure as diagnosed by a local chevrolet dealer, but being told that i am now out of warranty and it will cost $3500+ to repair. if there is a defect in the injectors, previously covered for 7 years/200,000 miles, why are the "new improved" injectors only coming with 12 months/12,000 miles. gm has a fuel injector problem with their duramax diesels that need to be addressed. i have read hundreds of post from people with the same problems. and chevrolet is not offering any help with any of them. i am dealing with gm now, and so far have gotten nowhere with the issue.

Reported in: LEEDS AL || Crash: N || VIN #: 1GCHK23144F

SERVICE BRAKES, HYDRAULIC

brake lines corroded and vehicle lost all brake fluid, thankfully while parked. vehicle is 7 years old, with low mileage, always garaged and driven a limited amount during winter, so exposure to salt was not high at all. this type of failure should not occur on a 7 year old heavy duty truck with 50k miles. thanks god it didn't lose brakes when towing a horse trailer..

Reported in: NWE HARTFORD CT || Crash: N || VIN #: 1GCHK29U14E

SERVICE BRAKES, HYDRAULIC

brake line near frame rail beneath drivers seat are corroded. one of the lines developed a leak and a loss of brake function resulted. all of the brake lines are completely corroded and need to be replaced.

Reported in: WOODSTOCK CT || Crash: N || VIN #: 1GCHK23U84F

SERVICE BRAKES, HYDRAULIC

brake line leaking due to corrosion. remaining lines also are excessively corroded. fuel lines also showing corrosion which i feel is excessive and premature.

Reported in: RUTLAND VT || Crash: N || VIN #: 1GCHK29294E

SERVICE BRAKES, HYDRAULIC

on feb..9 2012 i was in a drive thru automated car wash, when driving out i went to step on brake & the pedal went to the floor. i pulled over to the side lifted the hood & checked the master cylinder & saw that it needed fluid, i went into the convenience store & bought a pint of brake fluid, i filled the master cylinder, it took the whole bottle of fluid, i walked to the side of the truck to test the brake pedal & noticed the fluid leaked right out on the ground without stepping on the brake pedal. i had the truck towed to my repair shop, when put on lift the mechanic pointed out the rotted out brake line by the modular valve plus the other three lines were rotted & were unsafe, for a temporary fix i had the one line fixed by replacing a piece of the broken line. it was brought to my attention about the ongoing investigation with nhtsa. i purchased the truck in nov. 2003.

Reported in: BROOKSVILLE FL || Crash: N || VIN #: 1GCHK23164F

SERVICE BRAKES, HYDRAULIC

my sister inlaw borrowed my truck to move some boxes. driving down the road hit brakes pedal felt funny. second time she hit the brakes pedal went to the foor. luckly the second time was not a must stop situation. and got the truck off the road into a driveway. upon inspection i found the rear brake lines were severly corroded and leaking brake fluid. i think this should be addressed before somebody is killed or even a family is killed.

Reported in: FRANKLINVILLE NJ || Crash: N || VIN #: 1GCHK29U24E

STEERING

i am experiencing issues of serious rot and rust with components of my truck. first failure was that my power steering pump reservoir rotted through and caused a leak of fluid, had to replace unit. then transmission line rotted through, causing a leak of fluids, had to replace lines and cooler due to corrosion. then starter failed, seriously corroded. had to replace. afterward, alternator froze up, inside was corroded with rust and would not spin freely, had to replace. most recently, brake lines burst causing complete loss of braking ability. will need to replace. i have owned a substantial number of vehicles over the years and this is completely unusual in my experience and has caused a situation that could lead to death or serious injury. i was fortunate to escape both. furthermore, it has been a serious financial burden and inconvenience to have to replace so many components on a truck that has yet to reach 60,000 miles. i bought this truck new and have taken very good care of it in hopes that my 30,000 investment would last me a good number of years with regular and expected maintenance.

Reported in: SEVEN HILLS OH || Crash: N || VIN #: 1GCHC29U84E

SERVICE BRAKES, HYDRAULIC

Reported in: SEVEN HILLS OH || Crash: N || VIN #: 1GCHC29U84E

SERVICE BRAKES, HYDRAULIC

tl* the contact owns a 2004 chevrolet silverado 2500 hd. the contact stated that brake fluid leaked onto the driveway. the contact examined the vehicle and discovered that the brake line was corroded. the vehicle was taken to the dealer where the dealer confirmed the failure of the brake line. the manufacturer was contacted but the vehicle was not repaired. the failure and the current mileages were 58,000.

Reported in: SEVEN HILLS OH || Crash: N || VIN #: 1GCHC29U84E

ENGINE AND ENGINE COOLING

four exhaust manifold bolts have broken off since i've owned this truck and the manifold has cracked. it is a design flaw that occurs in many of the similar v8 equipped models and has been well documented on the internet. this should be recalled by gm. this problem also leads to faulty emission readings by the vehicle and the check engine light will go on and remain on until this expensive problem is fixed.

Reported in: PAINESVILLE OH || Crash: N || VIN #: 1GCHK24U64E

ENGINE AND ENGINE COOLING

my truck is a 2004 chevy silverado 2500 with 94000 miles and the rear driver side exhaust manifold bolt head is busted off. this is not the only chevy/gmc 4.8,5.3 or 6.0 engine that has this problem. millions of others have this same problem and from this failure it can lead to future emission problems, catalytic converter problems, exhaust leak in the engine compartment leading to exhaust fumes being leaked into the cab of the vehicle which would be carbon monoxide poisoning. this is a major issue that gm should take care of as a recall !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

Reported in: THORNTON CO || Crash: N || VIN #: 1GCGK23U24F

VISIBILITY:DEFROSTER/DEFOGGER SYSTEM

jan 2011 during a real bad winter we lost the front brakes while driving, multiple brake lines were replaced at a cost of $600+, april 2012 while driving again 25mph the rear brake lines burst!! just had to pay for more brake lines at a cost of $485. the truck now has 117,000 miles and this is not the first issue we have had, the odometer no longer works and had multiple problems with the blower for heat and a/c.

Reported in: DAYVILLE CT || Crash: N || VIN #:

ELECTRICAL SYSTEM

Reported in: DAYVILLE CT || Crash: N || VIN #:

SERVICE BRAKES, HYDRAULIC

Reported in: DAYVILLE CT || Crash: N || VIN #:

SERVICE BRAKES

while pulling up to a drive up window at a food store, the brakes went all the way to the floor. i heard the pressure releasing underneath. discovered that the left side brake line from the master cylinder to the abs module had burst from rusting through. there is heavy rust on sections of all of the lines. luckily, i was only going very slowly when is burst.

Reported in: YARMOUTH PORT MA || Crash: N || VIN #: 1GCHK29U34E

SERVICE BRAKES

due to brake failure on my wife's 2003 chevy 2500 hd silverado caused by corroded brake lines, i thought it would be wise to have the brake lines on my 2004 chevy 2500 hd silverado checked. upon inspection of the brake lines by fitzgerald auto in frederick, md (where i bought my truck, and where my wife's truck had just had its brake lines replaced), the brake lines were severely corroded. some areas of the brake lines were rusted so badly that they were flaking off. i was informed by the technician and the service adviser that replacement of the brake lines is imminent. and while it was already clear to me from the visual inspection, they both believed replacing the brake lines now was necessary to avoid brake failure in the near future. the total cost for my truck's repair was $1408.95. this is an 8 year old vehicle, and the brake lines should not be in such bad condition in such a short time. i have inspected my neighbor's 2004 ford f250 and his brake lines look brand new (though they are the original brake lines). i have inspected a 2007 chevy avalanche, and that vehicles brake lines look brand new (though they are the original brake lines). whatever material was used on my (and my wife's) model year truck(s), it was substandard, and causes a hazard.

Reported in: KEEDYSVILLE MD || Crash: N || VIN #: 1GCHK23104F

SERVICE BRAKES

started vehicle in driveway. stepped on brake pedal to shift into reverse. brake pedal went to floor, shifted back to park. shut off engine. looked under vehicle and saw brake fluid all over vehicle undercarriage and on driveway. vehicle is only 8 years and has less than 30k miles.

Reported in: WINTHROP MA || Crash: N || VIN #: 1GCHK23U44F

SERVICE BRAKES

i was driving on secondary road doing approx 30 mph, with 2 vehicles in front of me. the first vehicle hit brakes to turn into a parking lot, 2nd vehicle applied brakes , i applied brakes in my truck and pedal went to floor. fortunately i was able to avoid hitting the vehicle in front of me, ( a minivan with a woman driving and 2 or 3 children in the back seats) i was approx one mile from home and was able to get to my driveway by using low gear and i had minimal braking with pedal going almost to the floor. checked it in my driveway and found brake line had burst due to corrosion of steel brake lines. this vehicle has only 55, 271 miles and is 8 yrs old . from what i have read online this is a common issue with chevy trucks for years. chevrolet and the dealer i bought it from gave me the runaround and absolutely refuses to do anything about it, even though i have a extended bumper to bumper warranty that i paid $2,000 for.! with the number of complaints on this matter, i would think the nhtsb would force gm to do something about these issues as i am sure there must have been many accidents caused by this problem, and, i might add how many fatalities???. dealer service mgr. told me they put cheap lines in to keep costs down so people will buy them. heck of a great answer for something that brand new is approx $50,000 .

Reported in: BOW NH || Crash: N || VIN #: 1GCHK29U34E

SERVICE BRAKES

while driving at slow speed in a very congested area, the brake pedal suddenly got very soft and went all the way to the floor. braking became extremely limited. with the drivers window open there was the smell of brake fluid. if this failure had occurred 5 minutes earlier while braking from highway speed it would have certainly resulted in a serious accident. once stopped, a trail of brake fluid was apparent and a puddle had formed on the ground under where the driver sits. closer inspection showed one of the brake lines that runs from the master cylinder on the firewall to the abs control unit mounted to the inside of the frame rail on the driver's side had ruptured. this brake line, as well as the adjacent line to the abs controller, and the line from the abs controller to the rear axle showed signs of severe corrosion. the surface was red and large chunks of corroded brake line material were falling off. the abs controller, fuel lines in the area, and the frame rail itself showed very limited signs of corrosion typical of a 7 year old vehicle in a salt belt state. 8 months prior the vehicle was serviced by the dealer it was purchased and a report was submitted stating the brake lines were in good condition.

Reported in: MERIDEN CT || Crash: N || VIN #: 1GCHK23UX4F

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS

tl* the contact owns a 2004 chevrolet silverado 2500 hd. while driving approximately 10 mph, the contact abnormally depressed the brake pedal into the floor board. the vehicle was taken to an independent mechanic where the contact was advised that the brake lines were fractured due to corrosion and were leaking brake fluid. the front brake lines were also replaced because they were corroded and leaking brake fluid. the vehicle was repaired. also the speedometer would not display an accurate reading. the speedometer was not repaired. the approximate failure mileage was 97,000. updated 08/02/12

Reported in: SUDLERSVILLE MD || Crash: N || VIN #: 1GCHK29U24E

ELECTRICAL SYSTEM

Reported in: SUDLERSVILLE MD || Crash: N || VIN #: 1GCHK29U24E

SERVICE BRAKES

while stopping for traffic, brake pedal on my father's truck went all the way down, nearly causing me to hit the vehicle in front of me. limped the truck home using the emergency brake to stop. once home, noticed brake fluid leaking under truck. upon inspection, discovered brake line from abs module to ps front wheel was rotted through. noticed other brakes lines had significant surface rust. repaired line that ruptured. on 08/19/2012 while slowing for an intersection the brake pedal went all the way down again. limped it home again and discovered brake fluid leaking under two areas of the truck. line that goes from abs module to rear axle is rotted through and another line from abs module to front axle is rotted through. all the metal brake lines along the frame have severe rust on them. will need to replace all brake hard lines for truck to be safe.

Reported in: WEST TOWNSEND MA || Crash: N || VIN #: 1GCHK29U64E

SERVICE BRAKES

tried to stop pedal went to floor . upon inspection multiple brake line failures had occurred. *js

Reported in: CANDOR NY || Crash: N || VIN #: 1GCHK23U14F

SERVICE BRAKES

tl* the contact owns a 2004 chevrolet silverado 2500 hd. while parked, the contact noticed a leak under the front driver side of the vehicle. the contact inspected the vehicle and replaced the master cylinder. after the repair the failure continued. the contact later noticed power steering fluid leaking and noticed that the hydro boost unit would have to be replaced. there was a recall under nhtsa campaign id number: 05v043000 (service brakes, hydraulic) that could have been related to the failure. the dealer was made aware of the failure and advised the contact that the vin was not included in the recall. the vehicle was not repaired. the approximate failure mileage was 100,000.

Reported in: WEST VALLEY CITY UT || Crash: N || VIN #: 1GCHK23G34F

ENGINE

tl* the contact owns a 2004 chevrolet silverado 2500 hd. the contact stated that after starting vehicle, there was an abnormal noise heard from the exhaust system. the vehicle was not taken to the dealer or a repair shop for inspection or repairs. the contact stated that four of the six bolts on the exhaust manifold were missing their heads. the bolts were corroded and fractured. the manufacturer was not made aware of the failure. the contact notified the dealer of the failure. the failure mileage was 82,700. the failure mileage was 83,000.

Reported in: ALDEN NY || Crash: N || VIN #: 1GCHK29U24E

SERVICE BRAKES

brake pedal went to the floor while attempting to stop at an intersection for pedestrian traffic. because of the failure, a pedestrian was almost clipped.

Reported in: CONCORD NH || Crash: N || VIN #: 1GCHK29U44E

FUEL/PROPULSION SYSTEM

tl* the contact owns a 2004 chevrolet silverado 2500 hd. the contact stated that after engine startup, white smoke and heavy fumes emitted from the exhaust pipe. the vehicle was taken to the dealer who confirmed that the fuel injectors needed to be replaced. the vehicle was not repaired. the failure mileage was unknown and the current mileage was 208,163.

Reported in: TONOPAH AZ || Crash: N || VIN #: 1GCHC23104F

SERVICE BRAKES, HYDRAULIC

i was driving from the boat launch to park my 2004 chevy silverado 2500hd when the brake pedal went all the way to the floor. i pumped the brakes as i slowly approached my parking spot, however, i could not get any pressure to build up in the system. with no action on the brake calipers, i used my parking brake to stop as i entered my parking spot. there was no warning or indicator light alerting me to any brake problems. after parking i noticed a leaking brake line under the driver's side near the abs brake module. i made a temporary repair, attempted to bleed and pump up the brakes which resulted in the rear brake line blowing out right at the hose connection. still no warning or indicator light came on to alert me to any problems with the brake system. i had the vehicle towed home and as we were taking my vehicle off the truck, the brake warning light finally came on and the electronic dash displayed the message "service brake system". the lack of fluid in the brake reservoir must have triggered the sensor there. upon closer inspection, i noticed that the brake line failed inside a plastic brake line retaining clip located on the outside of the frame just before it was routed over to the abs modulator valve under the vehicle on the driver's side on the inside of the frame. i replaced all the brake lines with pre-bent stainless steel lines from classictube.com. i am only glad that this happened in a parking lot and not while i was towing my boat, i do not believe i would have had enough wits about me to use the parking brake to stop my truck. i mentioned this problem to my local gm dealer who blamed it on the treatment of roads during the winter months. granted living in the "snow belt" one should expect corrosion but never complete brake failure without any warning. there are numerous complaints online, just search for silverado brake failure.

Reported in: MOOSUP CT || Crash: N || VIN #: 1GCGK29U04Z

ENGINE

left rear and right rear exhaust manifold bolts have broken off causing an exhaust leak. causing potential vehicle emissions problems as well as the potential for carbon monoxide poisoning from exhaust gases getting into the cab of the truck.

Reported in: PENSACOLA FL || Crash: N || VIN #: 1GCHC29U74E

SERVICE BRAKES

my brake pedal went to the floor , i had my trailer with a tractor on i could have wrecked , i had to get my truck towed in and to get 3lines replaced do to rusty brake lines leaking, i was out $100 for towing and $375 to replace my brake lines, i had to get my lines with stainless steel lines so this would not happen again, as good has my brakes have been chevy should have went the extra step and put better lines on their trucks. plus the repair shop could not get pre formed lines they had to custom bend them.

Reported in: SAINT CLAIR MO || Crash: N || VIN #: 1GCHK23134F

SERVICE BRAKES

tl* the contact owns a 2004 chevrolet silverado 2500 hd. the contact stated that she heard a clicking noise near the dashboard and the brake warning light illuminated on the instrument panel. the contact then applied the brakes however, the brake pedal traveled to the floorboard abnormally and did not stop the vehicle. the vehicle was taken to the dealer for inspection where they advised that the brake lines were corroded and rusted. the vehicle was not repaired. the manufacturer was notified but provided no assistance. the failure mileage was 60,000. the vin was unavailable.

Reported in: 618-303-7058 IL || Crash: N || VIN #:

SERVICE BRAKES

tl* the contact owns a 2004 chevrolet silverado 2500 hd. the contact stated while driving approximately 25 mph he applied the brake pedal as he approached a stop sign and it extended to the floor. the contact immediately applied the emergency brake in order to stop the vehicle. the vehicle was taken to an independent mechanic who diagnosed that the brake lines were corroded and had burst. the brake lines were repaired. the manufacturer was not notified of the failure. the failure and current mileage was approximately 70,700. the vin was unavailable.

Reported in: YOUNGSTOWN OH || Crash: N || VIN #:

SERVICE BRAKES

i noticed that i had fluid leaking from the under carriage driver side. when i inspected it, i found that the brake line was rusted out and a leak had occurred. i then inspected the rest of the brake lines to find that all brake lines were rusted and some of the brake lines were flaking when i touched them. i then did some research online and found that there were many issues with the brake lines rusting out on the 2004 chevy silverado. this could have been a more serious issue if i was driving the vehicle and lost my brakes due to these lines rusting out. the vehicle also only has 76000 miles on it.

Reported in: PITTSTOWN NJ || Crash: N || VIN #:

SERVICE BRAKES

while on vacation and carrying a ruck camper, with no warning, brake pedal began losing firmness, going near floor. we were able to slow down and get to the side of the road, but brakes would not hold vehicle completely stopped. after a few minutes the pedal did become a bit more firm and we drove very slowly to a better place to stop. this time the brake warning light on the instrument cluster came on as we were stopping. there was very little fluid in the brake reservoir and brake fluid could be seem leaking it under the truck. the truck, and camper, were towed. dealer says all brake lines are rusted and must be replaced. very expensive - and dangerous!

Reported in: JOHNSTOWN OH || Crash: N || VIN #: 1GCHK29204E

SERVICE BRAKES

i was towing my trailer with brakes on it and as i was stopping at a stop sign the line between master cyl and abs unit blew out.upon inspector all the brake lines are i a very rusted condition mostly at the plastic line retainers.i am going to replace all lines to avoid a dangerous condition in the near future.

Reported in: PENDLETON NY || Crash: N || VIN #: 1GCHK29U74E

STEERING

to whom it concerns: i own a 2004 chevrolet 2500 hd 4x4 silverado. i bought it new. i have been hearing a clunking sound every time i turn the steering wheel left or right. this has been going on now for maybe 5 or 6 years. i started to look into the cause of the clunking sound because it sounds like it is getting worse, and i was very shocked to read so many complaints, over 50 when i stopped reading. it appears to me that this is not an isolated problem. my question is this. why does gmc not take notice of this problem and issue a recall before lives are lost because of this steering problem. i think it's a great shame that gmc will not take responsibility and get these problems fixed. thank you

Reported in: SALEM OR || Crash: N || VIN #: 1GCHK29U34E

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS

started vehicle in my driveway in front of garage, as i had my foot on brake, while placing transmission into drive, the brake pedal went completely down to floor, and the vehicle rolled backwards into garage door frame, causing minor damage to the aluminum flashing on the garage door frame. all attempts to pump brake pedal yielded no stopping effect. fortunately, this episode occurred in the driveway as my intended route included a steep hill ending at a "t" intersection. upon inspecting the vehicle, directly beneath the drivers door, there is a large puddle of brake fluid. upon further inspection, the fluid appears to be originating from a severely rusted brake line that sits above the frame leading into the abs controller. all the brake lines appear in the same severely rusted condition.

Reported in: MOUNTAIN TOP PA || Crash: Y || VIN #: 1GCHK23U34F

SERVICE BRAKES, HYDRAULIC

Reported in: MOUNTAIN TOP PA || Crash: Y || VIN #: 1GCHK23U34F

SERVICE BRAKES

corrosion of brake line resulting in total brake failure.

Reported in: LUCAS OH || Crash: N || VIN #: 1GCHK29104E

ENGINE

changed my oil and did a visual inspection on my engine. come to find i had two exhaust manifold bolts on each side that were broken. this needs to be resolved. i've heard of people having under the hood fires cause of this. this is a safety issue!

Reported in: TACOMA WA || Crash: N || VIN #: 1GCHK29U14E

SERVICE BRAKES

engine on passenger side all rusting exhaust manifold bolts rotted and broke off causing an exhaust leak that effects sensors. brake lines just bellow that rotted and just broke yesterday. luck ally i was only in my driveway at the time, ironic thing was i just left the shop for my safety inspection, sullivan tire derry nh 03038 should report them as well. this truck has a very severe problem with all parts on the passenger side of the motor rotting my repairs for all rotting parts 2100.00 these problems are unacceptable and should be fixed by gm . looking and reading online i am not the only one with these problems. seems to be happening on most all there 8 cylinder trucks and suv.

Reported in: LONDONDERRY NH || Crash: N || VIN #: 1GCHK23U94F

ENGINE

Reported in: LONDONDERRY NH || Crash: N || VIN #: 1GCHK23U94F

STRUCTURE:BODY

i was backing up to hook up my utility trailer and the brake pedal went to the floor. the trailer hitch crashed into the bumper of the truck..the brake lines had rotted through and the undercarriage of this truck is severely rusted.just a matter of time before the next issue with other lines or frame breakage.

Reported in: GORHAM NH || Crash: Y || VIN #: 1GCHK29U14E

SERVICE BRAKES

every year when it comes to getting an annual inspection on the truck, i always get the same response from the inspection station, failed because of faulty parking brake. i have to pay a mechanic every year to adjust the parking brake just so it can pass inspection. two years ago i got them replaced and paid almost $500 and this year i paid $100 for the shop to adjust them. in the end, brakes were adjust as much as they could and the truck would still roll with the brakes set. they gave me my inspection sticker, but i feel that gm should be required to use bigger brakes. gladly we live in a flat area but to those that live in a hilly area, this could really be a big problem. i ran a cross-reference, autozone.com, and the same parking brake shoes are used for both the diesel engine and the gas engine. the torque on the diesel is much stronger than the gas engine, which i know is the reason that the truck still rolls.

Reported in: EDINBURG TX || Crash: N || VIN #: 1GCHK23104F

SERVICE BRAKES

in driveway, started truck, applied brakes and the pedal went to the floor. got out, saw brake fluid dripping on the pavement on left side. saw severely (incredibly) rusted brake lines underneath. all brake lines at and near abs module terribly rusted, nearly disintegrated. had the failure happened while driving, an accident would surely have happened, especially if towing a trailer, which i sometimes do! i looked under my wife's toyota and see that the brake lines are all coated. surely gm should be using coated or stainless brake lines.

Reported in: WOODBINE MD || Crash: N || VIN #: 1GCHK29U34E

SERVICE BRAKES

i went to stop at a stop sign and the brake pedal went all the way to the floor. after looking at it, it was obvious that the brake line going to the rear brakes ruptured causing me to lose all brakes. the lines were all rusted and after doing a little looking online it appears that it is a very common issue with this year range truck.

Reported in: STARKSBORO VT || Crash: N || VIN #:

SERVICE BRAKES

i stopped for a coffee before going to work and when i got back into my truck and started it, the brake pedal went straight to the floor with very little pressure. upon inspection, i found that my drivers side rear brake line was severely rusted and had failed.

Reported in: SOUTHBURY CT || Crash: N || VIN #: 1GCHK29174E

SERVICE BRAKES

while traveling north on orrs bridge road (enola, pa) i was attempting to stop my vehicle at the red traffic signal at the intersection with wertzville rd. i was unable to stop when my brake pedal went completely to the floor and i had no brakes. fortunately there were no other vehicles stopped or traveling through the intersection at the time and i was able to travel through the intersection and stop the vehicle using the emergency brake. upon inspection of the vehicle i observed that both a front and rear brake line had failed do to significant rusting. i also observed that all the brake lines mounted in the locations of the failed lines were also rusted and where close to failure. had there been another vehicle stopped or traveling through the intersection, an accident would more then likely occurred.

Reported in: ENOLA PA || Crash: N || VIN #: 1GCHK23U04F

SERVICE BRAKES

complete loss of brakes due to brake line rupture and the subsequent loss of brake fluid. vehicle towed to gm service garage where inspection found brake line located under the drivers side of frame had rusted and rotten away. the service technician advised that the rest of the lines were poor condition as well. due to severe rust on the undercarriage of the truck frame, including the brake calipers, all four calipers needed to be replaced so the brake system could be bled. a cursory check on the internet and this web site seems to indicate a major rusting problem with the brake lines.

Reported in: SIDNEY NY || Crash: N || VIN #: 1GCHK23G14F

SERVICE BRAKES

arrived home, parked vehicle, noticed fluid dripping from under vehicle near front of driver's door area. inspection showed severely corroded brake lines, and one was dripping brake fluid from corrosion hole. all brake lines inspected and in need of replacement, which was done the next day.

Reported in: DAYTON OH || Crash: N || VIN #: 1GCHC29G84E

SERVICE BRAKES

at approx. 6:00 am i left for work which is a 15-20 minute drive. at the first traffic light i noticed the brakes seemed to be low. i continued my travels and at the next light i very nearly was not able to stop. when i reached my business and applied the brakes in the parking lot, they went to the floor and i had to coast to a stop in an empty lot. when i was able to park my truck, i got out of the cab and noticed the vehicle bleeding brake fluid from under the truck. i had to have to brought to my mechanic. upon inspection he found all the brake lines had rusted out and had to be replaced. early this year in january i had to have all the transmission cooler lines replaced in the same truck because they also rusted out completely. between the two repairs it has cost me over $ 1300.00 for a truck with only 30500 miles. this is absolutely ridiculous. if i had been on the highway at a significantly higher speed and my brakes failed in this manner, there would have been a major accident and someone could have been seriously hurt or killed. general motors/chevrolet should be responsible for the repair costs. they have known about the problem and have not notified the owners of their vehicles.

Reported in: WILBRAHAM MA || Crash: N || VIN #: 1GCHK29U34E

SERVICE BRAKES

brake failure on city street. this is the second time in a year i lost brakes due to brake failure. front brake line was replaced , now back line went. line is very rusty. *js

Reported in: SCRANTON PA || Crash: N || VIN #: 1GCHK29U04E

SERVICE BRAKES

a brake line ruptured as i attempted to stop at the end of my driveway (i was traveling downhill) on 1/3/2013. i experienced a loss of brakes without warning (no dashboard warning light). i was able to stop by using the emergency brake. i had the line replaced at this time. on 8/15/2013 i again experienced a complete loss of brakes when a brake line ruptured. again, i was traveling downhill on a driveway/farm lane and was able to use the emergency brake to stop. again, there was no warning from dashboard lights. i have had that line replaced also. i am now planning to replace all of the original brake lines. i have not had to do this on any other vehicle i have ever owned. *jb

Reported in: PORTERSVILLE PA || Crash: N || VIN #: 1GCHK23G84F

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:MANIFOLD/HEADER/MUFFLER/TAIL PIPE

exhaust manifold bolts broke off for no reason, letting exhaust fumes escape under the hood and in the cab of the truck. this seems to be a very common problem on several gm trucks. *js

Reported in: CONWAY SC || Crash: N || VIN #:

ELECTRICAL SYSTEM

oil pressure gauge quit working in about 2009. took into dealership and was told we were 4,000 miles past the recall of the cluster. very expensive replacement!! since that time the speedometer quit working, the tachometer quit working. very scary to be having to rely on temperature gauges that i hope are working correctly still, and a gas gauge that hopefully is also working correctly. i cannot believe they did not submit a full recall and replacement of this instrument cluster without an expiration on it. seems like this is a huge safety issue to me to have non working gauges due to a factory defect!!

Reported in: STERLING AK || Crash: N || VIN #:

ELECTRICAL SYSTEM: INSTRUMENT PANEL

the speedometer registers 120mph all the time when moving. was fixed once under warrant. the dealer who fixed it is no longer in business. i purchased a extended warranty, never used it. the truck has 55,000 miles right now. diesel. $43,000 new. chevy changed our onstar to digital. no onstar now.

Reported in: TIGRD OR || Crash: N || VIN #: 1GCHK29164E

SERVICE BRAKES

had no brakes. discovered ruptured brake line.

Reported in: GLENBURNIE MD || Crash: N || VIN #:

SERVICE BRAKES

while driving i saw a deer, it started toward the road i was traveling at 50mph the deer started to run to cross my path. i applied my brakes (i should have stopped in plenty of time but....) the pedal went down approximately halfway as normal and held firm, then the pedal continued to the floor, the brakes no longer slowed my truck impacting the deer. a similar incident happened two weeks prior. the first time the left rear brake line failed over the fuel tank. the instant incident the left front brake line failed two inches from the wheel flexible brake line joint. an automobile that is 9 years old should not have brake lines failing, this vehicle has just recently rolled over 100,000 miles mark and is used to pull the family rvs it is not a daily driver. why is steel used for brake lines? it rusts! why is it not coated? why not stainless steel? why put people's lives at risk using cheap materials that rust in a vital safety component such as brakes.

Reported in: CARLETON MI || Crash: Y || VIN #: 1GCHK29134E

SERVICE BRAKES

i got in the truck to leave my house. after starting the truck and putting my foot on the brake pedal i shifted into reverse to leave my driveway. at that time the brake pedal went all the way to the floor. i was able to shift back to park as i had not release the parking brake yet. i opened the hood and the master cylinder was empty. after looking under the truck, drivers side inside frame rail, i discovered a burst brake line where it leads into the abs module. all of the brake lines were extremely corroded and had to be replaced with stainless steel at a chevy dealer. i had the dealer perform other routine maintenance items at that time as well. they discovered that i needed to replace a chain guide in my transfer case, and repair a hole that the loose chain had caused. i find it hard to believe that chevy used stainless steel for the exhaust system, which looks great after almost 10 years, yet they used plain steel for the brake lines. i was lucky this occurred in my driveway, and not while i was towing my boat on the highway. the transfer case problem also seems like an engineering failure.

Reported in: ROCKVILLE MD || Crash: N || VIN #: 1GCHK23194F

SERVICE BRAKES

my truck was at a complete stop while in drive; at idle; with my foot on the brake pedal to prevent the vehicle from moving forward. without warning, the brake pedal went completely to the floor and the truck began moving forward. repeated attempts to push the brake pedal did not have any effect on stopping the truck. as the truck continued to move forward, i pushed down on the emergency brake pedal which did bring the vehicle to a stop. upon exiting the vehicle, i observed what appeared to be brake fluid dripping from underneath the driver side where 2 brake lines are located along the truck's frame. the leak of brake fluid is coming from the brake lines which are severely rusted. doing a simple google search reveals this is an extremely common, pervasive and persistent issue with gm pickup trucks since 1999, with some reports indicating it has continued to affect model years annually through the 2009 model. the repair cost appears to be running close to $2000 to replace the oem lines with stainless steel. why gm and nhtsa have allowed such a dangerous situation to continue for so long, with so many complaints, is simply remarkable.

Reported in: ELLICOTT CITY MD || Crash: N || VIN #: 1GCHK29224E

SERVICE BRAKES

after placing my foot on the brake to shift into gear the pedal went to the floor and i got a brake warning light. i opened the master cylinder cap and saw no brake fluid. i filled it up and the level kept dropping so i looked under the car and saw a puddle of fluid. i traced the fluid to the metal brake lines and noticed that they were all massively corroded to the point of having flakes of metal peeling off the lines. one of the lines had ruptured and was spraying fluid onto the engine making smoke and continued to drip even without the brake pedal being pressed.

Reported in: PARKERSBURG WV || Crash: N || VIN #: 1GCHK29U34E

SERVICE BRAKES

tl* the contact owns a 2004 chevrolet silverado 2500 hd. the contact stated that he started the vehicle and when the brake pedal was applied it was inoperable. the brake fluid was leaking underneath the vehicle. the contact took the vehicle to the dealer who indicated that the brake lines were corroded. the brake lines were replaced along with the master cylinder. the contact indicated that on january 8, 2013 he started the vehicle and the failure recurred. the vehicle was taken to the dealer who indicated that the brakes hydro boost system malfunctioned. the vehicle was not repaired. the manufacturer was notified of the failure and offered no solution. the failure mileage was 122,000.

Reported in: ABERDEEN MD || Crash: N || VIN #: 1GCHK24U34E

SERVICE BRAKES

returning from performing a drill operation and towing our drill machine back to the office. attempted to engage the brakes and all failed at approx. 60mph. i utilized the trailer brakes to bring the truck and trailer to a stop where i found a main brake line had split. having it repaired the mechanic advise me the entire brake system should be replaced due to corrosion/rust on all lines including the fuel line which could also fail. it was so bad that they did not attempt to bleed the lines as the bleeder may brake off. after that the truck has been stored until it can be repaired at over $2100.00 for only the brakes and does not include the fuel line.

Reported in: WINSTON SALEM NC || Crash: N || VIN #: 1GCHK24U94E

SERVICE BRAKES

i was traveling on a two-line road nearing the city and near the top of a hill when a line of cars slowed quickly in front of me. i had to get onto the brakes quickly to maintain a safe following distance, but when i did the pedal went completely to the floor. having very little time to react, i noticed the traffic in the oncoming lane had stopped or slowed greatly about 100 yards in front of me, so i was able to swerve into the left lane to avoid rear ending an entire line of cars with my 6000lbs truck. fortunately the driver at the front of the oncoming traffic saw me and stopped. i was then able to barely manage my way back into the right lane as some of those cars started moving again. at this point i was just cresting a large hill at approximately 40mph. a police officer in the oncoming lane had already seen me and activated his lights and then started working to turn around in the road to chase me. when i was back in the right lane i finally had a second to try to locate the parking brake, but activating it had absolutely no effect. i coasted nearly 1/2 mile down the road and forced the truck into a parking lot, over a large set of railroad ties and into a yard with an upsloped hill. if i couldn't have gotten it stopped there i could have coasted down an even steeper hill and into a very busy multi-lane intersection and killed someone. the police officer ended up being understanding of my situation and called a tow truck for me and i had it towed to a shop. the shop said that all of the brake lines were rusted out completely and both the front and rear sets of lines were leaking. i did not have any dash light indicating that the fluid was slow either before or after the incident. the shop owner also told me that these trucks do not have a proportioning valve in order to allow one of the front or rear brakes to continue working in the event of a failure.

Reported in: BELPRE OH || Crash: Y || VIN #:

SERVICE BRAKES

the brake line to the rear brakes failed due to rust (ruptured). this is the third chevy truck, of this generation, that i have owned; all three have experienced this failure. all three failed with no warning. i cannot believe people have not been killed; i was left with very little effective braking in all three events.

Reported in: YORK PA || Crash: N || VIN #: 1GCHK29U54E

SERVICE BRAKES

driving home from my wife's parents hose on rt 40, the traffic light changed.and when i depressed the brake pedal, the pedal went to the floor.i started to pump the brake pedal,and was lucky to stop my truck before i went throught the light.i was able to nurse my truck home.the next day i called my mechanic and had the problem taken care of

Reported in: ABINGDON MD || Crash: N || VIN #: 1GCHK23134F

SERVICE BRAKES

while stopped in a parking lot the brake pedal went to the floor. closer inspection revealed that the hard brake line had burst above the fuel tank on the line that runs between the abs module and rear axle.

Reported in: BLUE SPRINGS MO || Crash: N || VIN #: 1GCHK23154F

SERVICE BRAKES

while in traffic i pushed my brake pedal down hard to stop and it went to the floor. some braking resistance was felt by the vehicle but i still hit the car in front of me. there was only a minor scratch on the car i hit because i also hit the parking brake one the brake pedal didn't do anything. there was no warning light to indicate a problem but when i pulled off the road the brake line going to the rear brakes was squirting fluid. all of the brake lines on the car showed heavy signs of rust.

Reported in: LEVITTOWN PA || Crash: Y || VIN #: 1GCHK29124E

SERVICE BRAKES

tl* the contact owns a 2004 chevrolet silverado 2500 hd. while the vehicle was being serviced for routine maintenance, the mechanic noticed that the entire front end of the vehicle was defective. the mechanic replaced the steering box, pitman arm, outer tie rod on both ends and the upper ball joint. the contact also stated that the brakes were leaking. the brake leak failure had not been repaired. the manufacturer was not notified. the vin was unavailable. the approximate failure mileage was 200,000.

Reported in: HIDDENITE NC || Crash: N || VIN #:

SUSPENSION

Reported in: HIDDENITE NC || Crash: N || VIN #:

STEERING

Reported in: HIDDENITE NC || Crash: N || VIN #:

SERVICE BRAKES

i was leaving my home to do an errand, while nearing an intersection i applied pressure to the brake pedal when it dropped to the floor . i had to apply serious pressure to get it slowed enough to turn around to head uphill towards home. notice i said slow down, not stop. had i gone seconds further i would have been in far worse shape as there is a steep decline for about 3/4s of a mile just past the intersection where the line gave out. i have had brake lines go bad before in other vehicles but was always able to stop the vehicle within a reasonable distance. i think if i had been on a main road with traffic and a generally faster speed allowance there would have been an accident. something should be done to better supply the use of front brakes when the rear brakes fail and vice versa.

Reported in: NAPANOCH NY || Crash: N || VIN #: 1GCHK29U64E

UNKNOWN OR OTHER

driving a 2004 chevrolet 2500hd 4x4 6 liter crew cab with 143005 miles. traveling at 55 mph as i approached my turn onto a side street at approximately 100 yards out i applied brakes to reduce speed to 15/20 mph to make 90 degree downhill right turn. i experienced a very spongy brake for a couple of seconds followed by the brake pedal going completely to floor. i pumped brakes several more times with the same brake pedal response and zero braking. my speed had only dropped to about 40 mph, too fast to negotiate my turn. i continued on the hwy to the next street using my parking brake and down shifting. safely parked, i got out of truck and noticed a large amount of fluid was running on the ground, drivers side forward part of cab, resulting in a complete loss of brakes. my left front steel brake line located on top of frame under driver side at firewall had burst. all 4 brake lines in that 4" long area were badly rusted. removed all the brake lines and that appears to be the heaviest area of heavy rust.�

Reported in: SEWANEE TN || Crash: N || VIN #: 1GCHK23U64F

SERVICE BRAKES, HYDRAULIC

Reported in: SEWANEE TN || Crash: N || VIN #: 1GCHK23U64F

SERVICE BRAKES

a badly rusted brake line burst while i was stopping for a stop sign. i managed to stop the vehicle without incident and get it home, but upon inspection, i found that all of the metallic brake lines which run to the rear of the vehicle are rusted to some degree. the line which burst runs along the frame in the vicinity of the gas tank. i own a 1971 jeep commando which still has its original metallic brake lines, and they are not the least bit rusty. it is disturbing to me that a modern vehicle would be constructed with materials inferior to those used more than 40 years ago.

Reported in: FORK UNION VA || Crash: N || VIN #: 1GCHK23264F

SERVICE BRAKES

while driving under good conditions, sunny, dry road surface, approximately 65 degrees, asphault conditions excellent, not in traffic, no cars in front of me, no cars behind, the truck was empty and had only one person, the driver. i started to slow for an intersection and the brakes did not respond. the pedal went all the way to the floor. i was at least 400 ft from a traffic light equipped intersection at the time. i was able to down shift. the truck is equipped with some very low gearing for towing and by shifting down through the gears i was able to stop before the intersection. the brakes had very little stopping power left. there was no indicator that i was losing brake fluid pressure. however had i been on a highway, the truck fully loaded, in heavy traffic or on a big hill this could have turned out much worse. reviewing the brake lines you could see that they were uniformly corroded on all exposed lines.the corrosion is heavy and it makes it difficult to determine the surface condition of the brake line. a leak had developed at a bend, in the line, just under the master brake cylinder. you really cannot see the leak due to the surface condition. you know it is there due to the visually seeing the brake fluid spurting out. all of the brake lines on the front end of the truck must be replaced and due to what i would consider defective brake line material i will have all of the lines replaced. i state that i feel they are defective or of extremely inferior quality do the fact that other lines in the truck show no corrosion at all, such as the ac lines, the lower transmission lines, lower gas line, these while tarnished are not corroding. this is the first failure of this type on the truck. previously i had an exhaust gasket break and the alternator fail all other work has been maintenance type work such as oil changes. i purchased the truck new.

Reported in: NORTON MA || Crash: N || VIN #: 1GCHC23UX4F

ELECTRICAL SYSTEM

one by one, the gauges on the dash have stopped working, starting with the engine temperature gauge. then the fuel level gauge, speedometer, tachometer, oil pressure, and finally the transmission temperature gauge all went out, leaving only the battery voltage meter working correctly. i know at least three other people living within 20 miles of my house that have also had this problem with their 2004 silverados.

Reported in: PRAIRIEVILLE LA || Crash: N || VIN #: 1GCHK29254E

SERVICE BRAKES

pulling boat trailer up out of the boat ramp and brake peddle went to the floor and leaked out all the fluid had it towed to garage and found brake line had rusted through on one of the 4 others were in bad shape lucky i wasn't towing the boat down the highway and had to stop i could have killed someone or myself gm needs to address this problem now i hear there has been a lot of complants

Reported in: PENNSVILLE NJ || Crash: N || VIN #: 1GCHK29274E

SERVICE BRAKES

i was planning on heading up to the mountains to my cabin today (8/10/2014). i stopped for diesel at king's quick stop, about 3 blocks from my house. after i filled up, i put it in drive and the brakes failed completely. by the grace of god i was only going 5 mph in the gas station parking lot or i could have easily hit cars or pedestrians causing injury or loss of life. i drove home using the emergency brake which is not in a great place for emergency stopping. after arriving home i took a look and discovered that the brake lines in one particular section were completely corroded and one of them had burst. this is a vehicle that i frequently drive to the mountains and i cannot fathom how this could happen on any truck, let alone a heavy duty truck. no warning light came out to inform me that my brake pressure was low although i figured that out quickly when my foot went all the way to the floor. after diagnosing the problem, i did some searching on the web and discovered this is a common problem in the salt belt states. but i live in north carolina so this is quite a surprise. i will be scheduling repairs tomorrow but my understanding is that gm is not assisting in any way and that the repairs can run up to $2000. i've owned 20 cars in my lifetime, many with excessive mileage and have never had brakes fail before. so this is quite unsettling and clearly gm has a faulty and dangerous design here.

Reported in: LANDIS NC || Crash: N || VIN #: 1GCHK23244F

SERVICE BRAKES

i was driving and went to stop the brake petal went to the floor. i put the shifter into low 1 and hit the emergency brake to come to a stop just short of hitting the honda civic in front of me with the baby in the back seat. i put my hazards lights on and checked the truck. under the bed was wet with brake fluid. the brake line was rusted through and is snapped letting all of the fluid out. so, no brakes!

Reported in: CHERRY HILL NJ || Crash: N || VIN #: 1GCHK29U14E

SERVICE BRAKES

on saturday, august 11, 2012 i experienced a brake failure. after looking underneath my 2004 chevy silverado 2500hd brake fluid was dripping from a rusty brake line below the driver seat area. it appeared i lost the rear brakes so i was able to get the truck to the chevy dealership the following monday august 13, 2012. this truck only had 49,364 miles on it and was approximately 8 years old. the chevy dealer later called me with the bad news that all of the brake lines were bad and needed replaced. they also discovered the fuel lines were rusty and needed replaced too. they later notified me the calipers were rusty as they could not bleed the brakes properly so these also had to be replaced. the total of this august 21, 2012 invoice was $2,772.28 and this was with a 10% discount. please note the rear brakes were just replaced 1207 miles earlier on april 30, 2012 for my required state vehicle inspection. during this state inspection (mileage 48,157) in april 2012 they also had to replace a speed sensor as the truck was going into abs at low speeds. the invoice states this sensor �came apart� and they also had to clean the other one. there is was no indication of rusty brake lines or fuel lines brought to my attention during the april 2012 state inspection and on august 11, 2012, just over three months later i experienced total rear brake failure. i certainly feel this was a sudden loss and could certainly lead to future collisions, injury or potentially death if something is not done to try to correct this brake line corrosion problem. i am thankful i was not towing a heavy trailer when this occurred and that no one got hurt but it could have been much worse. i�m glad they found the fuel line problem as this could have caused a vehicle fire or a house fire if the truck was parked in the garage if this fuel line corrosion was not corrected. thank you for listening.

Reported in: CHARLESTON WV || Crash: N || VIN #: 1GCHK23U14F

SERVICE BRAKES

just finished a 300 mile trip towing a 24 foot race trailer. next morning left to put the trailer in storage and the pedal went to floor on the way out of the subdivision. luckily the speed was slow and the trailer had brakes so i could get stopped by using the omg switch on the brake controller. there was cross traffic that would have resulted in a bad accident had i entered the intersection. judging by the number of complaints of rusted brake lines on this vehicle it is only a matter of time before someone is killed. further inspection of the vehicle shows that all the lines need to be replaced. this truck is maintained in like new condition and brake lines should go many more years than this.

Reported in: ROCKFORD IL || Crash: N || VIN #: 1GCHK29164E

FUEL/PROPULSION SYSTEM

while driving in heavy denver, colorado traffic late afternoon hours of 07/18/2014, my 2004 chevrolet silverado 2500 hd, duramax lly had a "significant reduction of engine power". gm was aware of this as early as august 17, 2009, as per their bulletin # 09-06-04-034. this bulletin states this may be caused by the fuel injector wire harness rubbing against the bracket and chafing the wire insulation. this occurred on my vehicle causing one wire to short against the bracket. this immediately shut down the affected cylinder bank resulting in an immediate reduction of engine power. i feel this could be a safety concern. fortunately i was able to get to the side of the roadway without incident. i have sent three emails to gmprioritycare@gm.com

Reported in: CHINO VALLEY AZ || Crash: N || VIN #: 1GCHC23274F

SERVICE BRAKES

stepped on brake and put vehicle in drive. drove to end of driveway and stopped. the pedal went to floor after stopping. upon investigation i noticed the brakeline running from front to back of vehicle broke. same time i also noticed that the entire brake line system was rusted and falling apart.

Reported in: BARNEGAT NJ || Crash: N || VIN #: 1GCHK24UX4E

SERVICE BRAKES

my wife, daughter, and i were traveling down a two lane highway at the 55 mph speed limit. a oncoming vehicle pulled out to pass another vehicle. when i stepped on the brake pedal to avoid a collision, the pedal went all the way to the floor. thankfully, the oncoming vehicle went back to their lane and we were able to coast to a stop. upon examination, all four brake lines on the front half of the truck were badly rusted and leaking. the undercarriage on our 2004 chevy silverado is extremely rusted. fuel lines. transmission cooler lines, brake lines, frame, body panels all have large amounts of rust. we purchased this vehicle new in 2004. it has never been in a flood.

Reported in: GREENCASTLE IN || Crash: N || VIN #: 1GCHK29U84E

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