Five problems related to brake disc caliper have been reported for the 2002 Chevrolet Suburban. The most recently reported issues are listed below.
Passenger front brake is locking up while vehicle is in motion. Has caused numerous brake pad replacements and caliper and rotor replacement. Has cause small fire.
When driving from work, my husband noticed the vehicle was slow to stop. When the vehicle finally arrived home, we noticed a sizable amount of brake fluid in the driveway. The trail led all the way to the garage. Since I cannot safely drive it to a mechanic for a formal assessment, my husband went under the vehicle myself and noticed it had excessive corrosion throughout the entire undercarriage. It is especially, extremely, and exaggeratedly severe with the brake lines. There is a small metal junction where the rear brake lines branch out to the respective left and right hub/caliper. The lines branching from this small union -that is just above the spare tire- are very wiry. He also noted that all of the lines from the front of the vehicle to the back, have a lot of corrosion on them.
My wife was driving our 2002 Chevrolet Suburban 1500 4wd when she applied the brakes to stop the peddle went all the way to the floor. She was able to get the truck into a parking lot without incident. When I got there to look at the problem, I noticed the steel brake line supplying the right front caliper was severely corroded, where it runs atop the frame in the engine compartment, to the point where it developed a pinhole to allow a loss of pressure(peddle). The line is so corroded that I can't even cut out a section and flare the old line to install a repair section of line. I believe the entire brake line has to be replaced. At this time I haven't inspected the rest of the lines, but when I can I will!!!!! I'm reading about numerous brake line and other severe corrosion issues on these models. We have been loyal gm customers since 1976. We currently own the above mentioned Suburban and a 2008 silverado. The Suburban is our primary family vehicle which is used to transport our disabled child.
The truck has been to the dealer because the brakes would not immediately grabbing and the truck was taken to a dealer for repair of the rear backing plates which began to rust and break apart. This was repaired by the dealer. The dealer had to replace the brakes, calipers, and rotors along with this repair. Both rear brakes and housing assemblies were also replaced, the dealer noted they too were rusted. About a week after the repair while driving there was a hissing noise and thought that the tire may be going flat. The tire was not flat. The contact slowed at a stop sign, and when applying brake pressure there was a grinding and clanking noise each time brake pressure was applied. The contact drove home. Upon inspection of the vehicle noticed the caliper fell off and there was a grove on the rear drivers side rim. The vehicle has been back to the dealer. The dealer towed the vehicle back to the shop and determined there was a bolt from the caliper that had snapped and caused the caliper to fall off. The dealer is currently completing repairs on the vehicle. Nhtsa recall NHTSA 05v379000 involving the anti lock brakes was issued , but contact was unsure if this vehicle was covered under the recall.
A bolt securing the rear left brake caliper bracket assembly failed catastrophically jammming the brake and the rear wheel while in motion. Fortunately this occurred at low speed and was controllable, but if it had occurred at speed on the highway, there would have been a major accident since the rear wheel could have suddenly seized with resultant loss of control of the vehicle (2002 4wd Suburban z71).