Brake Disc Caliper problems of the 2002 GMC Sierra 1500

While traveling at approx. 20-25mph, pulling away from my home, a small animal ran across in front of me. I hit the brakes, hard, and after a momentary feeling of brake pressure, the pedal went straight to the floor with no brakes whatsoever. I backed up into my driveway, jacked up the truck and placed it on jack stands. The underside of the truck was wet and dripping brake fluid around the abs unit beneath the cab. My wife applied the brake while I examined the underside. An approx. 1/8in hole was found in the incredibly rusty and weak steel line running from the abs to the left front where it joins the rubber line to the l/f caliper. Further examination reveals all steel brake lines are incredibly rusty, structurally weak and in danger of failure. This could lead to a very serious, catastrophic crash with the potential of fatalities. Further, all of the steel parts of the fuel lines are also very, very rusty and weak and with the high internal pressures and highly flammable and explosive gasoline inside are another serious hazard. I am a licensed master auto/truck and motorcycle mechanic. In nearly 50 years of driving I have never seen a brake line failure from such massive rust on a vehicle with such low mileage. This vehicle has only 68,830 miles on it. It is unsafe to drive. Many, many other owners of similar GMC and Chevrolet trucks have reported similar brake line rust and failure. Repair/replacement cost estimates can be as high as $1200 to nearly $2000. Brake line failure can kill. If ever there was justification for a safety related recall, this is certainly it.

Moments after leaving the driveway at our home, approaching an intersection at about 25 mph, I applied the brakes on my 2002 GMC sierra, and the pedal went to the floor. I couldn't stop the vehicle before going through the intersection. Fortunately no other vehicles were in the intersection and no accident occurred. After returning the vehicle to the driveway I discovered brake fluid under the truck bed and dripping from the frame. I could not see the source of the leak as it was well hidden either in or above the truck frame. I had the vehicle brought by flat bed truck to a local auto repair garage. The mechanics found the brake lines to be heavily rusted and one had rusted through and failed, causing the earlier brake failure. Because the brake line rusting was so heavy, all the brake lines were replaced. Also,, the two front brake calipers were replaced because of heavy rust. The rusted brake lines are available. The consequences of this was a repair bill of $1149. 78, and having my truck in the shop for several days. Luckily, nobody was hurt. If this had occurred later in the day in the same location it may not have turned out the same. This is the third major brake repair done on this truck. I am the original owner. I have had to have the brake pads and rotors replaced twice. Both times I was told the rotors were so badly rusted they needed to be replaced. During the first six years of owning the vehicle it was kept in a garage. It has always been well taken care of. With this repair, I have spent over $3000. To keep brakes functioning on this truck.

Brake line failure on my 2002 GMC Sierra 1500 1/2 ton 4wd pickup. Brake line failed because of rust. My truck has only 47000 miles on it and well cared for. When it happened I was turning into a parking lot and the brake pedal went to the floor almost hit street sign. I had to get the truck towed. The garage had to replace all brake lines,front hoses and calipers because of rust. The total bill came to $1030 including the tow. The garage told me they have to replace these brake line on these early 2000s gm truck all the time. There has to be a recall on these truck because you have no warning when this happens. Very scary when it does.