Two problems related to brake disc caliper have been reported for the 2004 Chevrolet Silverado 2500. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2004 Chevrolet Silverado 2500 based on all problems reported for the 2004 Silverado 2500.
Brake lines and related calipers continue to rust and fail. Have now lost brakes while driving due to failure of various brake lines three times. Twice I lost the brakes while driving in highway traffic. Once while backing slowly down a ramp to a dock. Have had lines replaced 3 times now. Calipers also replace. Vehicle in shop for emergency repair now. Previous dealers have said this problem is related to the new brine material applied to roads by dot in winter. Note that I do clean undercarriage to remove salt. Also have had several older vehicles other makes/ models during same time period and have not had this issue. Never replace brake lines on other vehicles.
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.