Brake Disc Caliper problems of the 2004 Chevrolet Silverado 1500

2004 Chevrolet silverado experienced complete brake failure. Driving down a short hill, brake pedal pushed completely to floor with no brake response or stopping availibility. Driving @ approximately 20 mph, applying the emergency brake had little effect and had to turn into a dirt hill to stop the truck. Upon further inspection, 4 brake lines direclty underneath the cab on the drivers side were completely corroded with 2 lines failing simultaneously releasing brake fluid onto the ground. The 2 lines from the proportioning valve in the engine compartment to the abs and the 2 lines from the abs to the 2 front wheels run parallel under the cab and are severely corroded in 2 places only. The 4 lines were severely rusted at the point of the plastic clips that secure the lines to the frame of the truck. The plastic clips that hold the brake lines hold moisture and salt and cause all the brake lines to corrode at those points. It's important to note that there is no rust in the lines to the rear of the truck or at both rear brake calipers. This is not normal wear or lack of maintenance. I clean the underside of my vehicle every winter. The lines are rusting as a result of the clips retaining salt and corrosives and causing year round contact to the brake lines. Is anyone reading or investigating here? there are literally hundereds of complaints here regarding this exact issue. I have seen multiple post thast list the corrosion in the exact same spot as my truck. These lines rust not from normal wear but because of a defective clip design. Repair estimate from Chevrolet dealer is $1250 to replace all lines. When will gm consider this a defect or write a service bulletin?.

First incident: upon leaving work, I merged onto the highway, travelled around the circle, stopped, crossed onto another highway, stopped again, accelerated normally, reached approximately 40 mph and had to hit the brakes hard to stop because of traffic in front of me stopping short. The next time I depressed the brake pedal, it travelled nearly to the floor. The line from the abs unit to the rear brakes had cracked. I was able to get the vehicle to my garage where I removed(and saved) and replaced the line. Second incident: Tuesday, February 19th. On my way to work, normal driving and braking, approaching a traffic light, light changed to yellow, I was going approximately 50 mph, depressed brake pedal, pedal continued to travel and I was able to stop in the middle of the intersection after the light had turned red. No accident or injury. I will most likely receive a ticket as the light has a camera that photographs anyone running the light and sends them a ticket in the mail. This time, a line going to the passenger side front caliper broke. I was able to get the vehicle back to my garage where I cut out and began the difficult task of replacing this line. I also noticed the line going to the driver side front caliper was equally rusted, but had not broken yet. It is now Thursday, February 21st. I have missed 3 days of work and now I will have to have my truck towed to the dealership I work at where I will most likely have to remove the body of the truck from the frame to properly install new brake lines to the front calipers. I have saved the old brake lines as evidence. They look more like rotten twigs than they look like steel brake lines. It's disgraceful that a vehicle only 9 years old would need all new brake lines when I have had several old vehicles from the 70's and 80's which had original brake lines that did not break. Only surface rust appeared on them.

When I had the oil changed I had the garage check the brake lines since I had heard of many failures. They determined and showed me that the lines were corroded and the connections to the calipers were also so corroded that they broke when they tried to remove them. I had everything replaced to prevent a failure of the system.

Although I have not had an accident, the brakes on my 2004 silverado k1500 are dangerous. The pedal is very soft and when pulling a 4000# travel trailer I have serious problems stopping safely. I have had to take the shoulder on one occasion to avoid hitting another vehicle. Even when empty, it takes an excessive distance to safely stop. My dealer has told me the brakes are within gm specifications, but has also told me what I can do to improve them. At my cost of course.