Brake Disc Caliper problems of the 2002 Chevrolet Silverado 1500

There is a major safety design flaw in the 1999-2002 brake system. The front tires through the salt and grime from the roads onto the brake lines where Chevrolet has located them in the design. This causes the brake lines to corrode and burst during driving. Mine have now burst for the second time in the last 5 years. The first time in 2013 I was driving at about 35-40 mph when I went to make a rh turn and the brakes went to the floor. This time I had went to a local gas station and was on the way home when I stopped to talk to a neighbor and once again the brake pedal went to the floor. I drive the truck very little so I have only put just over 17,000 miles on the new set of brake lines that I had installed by a Chevrolet dealer in 2013. I live in southern indiana, just north of louisville, ky so our winters are not that harsh, so the amount of salt from roads is pretty limited. I have talked with other Chevrolet silverado, yukon and suburban owners and they all share having the same issues with their brake lines. I have went to youtube to see how to make the repairs myself and have seen countless videos on individuals repairing their brakes because of the corrosion and the brake lines bursting. Come on nhtsb what are you waiting on before you issue a recall, someone to die or be permanently disabled! do the right thing and issue a recall to fix the brakes with stainless steel lines, rotors, calipers and brake pads that will not rust after a few years!.

While traveling through town approached an intersection when brakes were applied pedal went to the floor tried to pump them as fast as possible to not get into a collision with car sitting at the red light. Did an avoidance manuver into right turn lane was unable to stop truck and narrowly missed oncoming traffic turning left as I approached the corner, I shifted transmission into low gear and was able to apply parking brake to stop truck. Took to mechanic and found brake line ruptured below drivers seat had to replace all brake lines due to corrosion . Was informed by mechanics repairing the ruptured line could break surronding lines as they were all corroded as well. So they replaced all brakelines and all piston calipers as well because ferrul nuts were rusted into calipers. $1600 dollar repair. Lines and calipers (4).

Took truck in for state inspection, truck failed inspection due to rusted brake lines, power steering pump leaking , dealer said it would be $1228. 43 to $1420. 99 to just fixed the brake lines all lines needed replaced and calipers screws. Power steering pump cost 535. 00 to replace. Poor quality ,high cost to fix and lack of safety on gm part for not covering rubber coating or using stainless steel lines to protect our family very discouraged with service tech said these are the prices. What happened to our safety. Brake lines and gas lines should not be made of steel that can corrode and rust out and break. Power steering pump with these few miles should not have gone out. My 1988 chevy truck never had these problems. There needs to be a recall.

I got off work, pulled up to get onto main road brakes felt spongy, did stop, got onto main road traveled 1/2 mile about 35 mph, slowed truck by letting off gas to make right turn, tried to use brakes to slow more, brakes went to the floor. I managed to get slow enough to make turn safely. I pretty much traveled 5-10 mph another 50yds to get into lowes parking lot. I tried to brake again, no brakes. I put truck into neutral and coasted to stop. I got out of the truck smelled brake fluid. Brake fluid was everywhere around my driver rear wheel. I called a tow truck to get my truck home thinking my caliper or hose failed. After taking off my wheel, I found that the steel brake line was ruptured. Called a mechanic to see if he could take a look at it, he said he could maybe late Friday, he just did a 2004 silverado with the same problem. I called a tow truck again to get truck to his garage. He calls me late Friday evening and said all the brakes lines have to be replaced because of heavy corrosion and maybe the calipers depending if they fail. He quoted me a price at $900. My CO-worker had his brake lines replaced not to long ago and his is a newer model.

March 27, 2010 rear driver side brake line burst on 2002 chevy silverado while on highway. When brought in for repair 2 new calipers were needed due to extensive corrosion. Repairs came to $617.

The contact owns a 2002 Chevrolet Silverado 1500. The contact stated that when approaching a stop sign or traffic light, the abs engages too early and the brake pedal vibrates. The vehicle was taken to a service station and it was discovered that the calipers needed to be replaced due to rust build up. The VIN was unknown. The current mileage was 105,000 and failure mileage was 10,400.

This vehicle, at 46,000 miles had to have all the rotors and brake pads and two calipers replaced because they rusted up and locked up. Had to do it again about 65,000 miles, then had a back caliper seize up and replaced both rotors and one caliper along with new pads. I then had to have all the rotors replaced, both front hubs, one new caliper and pads again at beck Chevrolet a year ago. On my way down to FL this past fall, with about 84,000 on the truck, another caliper seized up and had to replace the caliper, both back rotors and brake pads. Yesterday, 3/27/13, on my way home from town, with 85,000 miles on the truck, the pedal went to the floor and no brakes. Inspection showed a ruptured brake line on the driver's side. My repairman said every brake line is swiss cheese and need to be replaced. This is ridiculous. I've spent several thousand dollars and have replaced brakes 3 times, all rotors, most calipers and two front hubs because of rust. The frame and everything under my truck is rusted very badly. I've owned this truck since 2004, and bought it when it had 26,000 miles on it. It drives beautiful and is like new, but it's going to rot right out from under me. Please help!.