Brake Disc Caliper problems of the 2003 Chevrolet Tahoe

Hard metal brake line failure during emergency, high pedal pressure, stop. No injuries. The vehicle was unable to avoid entering an intersection, as the lead car. Braking was firm, before pedal descended steadily toward the floor. Pumping provided some friction, but was unable to restore a minority of the system's capacity. The failure was a hole developed in the line, along its path to the passenger front brake caliper. The brake lines showed alarming corrosion levels, which while potentially understandable for a 13 year old northeast outdoor winter truck, was a symptom of catastrophic potential.

Complete failure of brake lines and calipers secondary to rust. Truck (a gm Tahoe) was inspected at the dealer one month ago and passed PA inspection. Approximately 1 month later (1000 highway miles) my truck had to return to the dealer to rectify something they had previously been fixed, unrelated to the brakes. Upon picking up the truck after that repair, the brakes were applied after starting the car to put into gear and the entire break system blew. Thank goodness, the vehicle was not in motion because I would not have been able to stop. The dealer them put the car up on the lift and I was told the entire system was rusted, including all the bolts to the system. The only way to repair was to cut the entire brake line system off and replace. The rear caliper covers also began to rust, so they are also being replaced. I can provide pictures of all areas prior to repair.

In Nov. 2011, with 79,800 miles, while in my driveway, the brake petal collapsed to the floor. Two front brake lines burst with no warning. There was almost no rear braking power at all. I had to push the petal to the floor, before the rear brakes engaged and barely stopped the Tahoe in my driveway at 5 mph. My 03 Tahoe and my dad's 06 Tahoe have the weakest brakes, of any vehicle we've ever owned. Love the Tahoe-hate the brakes. I had the lines replace and had to replace the front calipers as well. The aftermarket calipers helped the weak braking problem a little, but there is still a design flaw somewhere. Now in Aug. 2013, with 90,200 miles, two more brake lines burst with no warning, while driving 25 mph, again with almost no rear brake power to stop. I barely missed crashing the truck. It's in the repair shop now and the Tahoe needs several lines replaced, 2 that burst and others that are extremely rusted, obviously about to burst. The nhsta needs to look at, not only the rusting brake lines, but also into the weak breaking system on these trucks, including why the rear brakes are so weak. Seems that about 90-95% of the braking power is the front brakes. This problem is discussed all over the internet. This is a serious problem on the Tahoe, from 2000-2006, and this entire brake system should examined and even recalled, it's weak, dangerous and unreliable.