Two problems related to service brakes have been reported for the 2002 Chevrolet 2500. The most recently reported issues are listed below.
Rusted break lines.
Late on July 30, I had a single vehicle accident. I was driving down the interstate / toll road on the way back from the airport. I had cruise control set to 75mph. With no warning, my rear wheels locked up. My truck skidded into a bridge. State farm recommended my vehicle be taken to purifoy Chevrolet for repairs. When I was notified by purifoy and state farm that my vehicle was repaired, I asked the purifoy shop manager, my state farm agent, and my state farm claims representative if the vehicle had been inspected for the cause of the locked-axle condition which caused the crash and injured me. All stated the vehicle had been inspected, repaired, and certified safe to drive. I paid my deductible and drove home the vehicle and parked it in my garage. Within days, I used the vehicle and the axle locked up again - badly worsening my physical injuries from the first crash and causing me to be put into several more weeks of physical therapy. I am still under a doctor's care. And, I am still in physical therapy recovering from the injuries. My physical therapist has noted into my medical records that the second occurrence greatly prolonged my healing by adding additional injury to that which previously occurred from the first crash. After this second occurrence, I took my vehicle to a local shop. The shop manger locally stated this was a well-known condition of Chevrolet trucks: the rear axle vent tube was manufactured too small; the tube plugs; this forces axle grease into the emergency brake hub; the emergency brake becomes saturated and swells to close proximity to the hub; when the brake heats up, it automatically applies and cannot be released until the wheel rolls slightly backward. The local shop manager replaced both axle seals, cleaned and resized the vent, and installed new emergency brakes. This corrected the locked wheel/axle condition.