2004 Chevrolet Silverado 2500: ABS light or ABS activating

Filed Oct 27, 2015 · Brakes · 164,000 miles · PA

Brakes failed under hard stop (highway, in motion) to avoid a collision with deer. Master cylinder to ABS module steel brake line failed in a mode of rupture due to corrosion. All other steel lines were corroded and contacted gm. 2 other silverado line vehicles owned also failed this year due to corrosion. Gm response was that no recall existed. Replaced all steel brake lines in vehicle with stainless aftermarket lines. After multiple contacts with gm customer service, I was told to save my receipts for repairs. This is an incorrect material specification, latent defect and gm needs to be held accountable. 3 vehicles that I own with the same repair in 8 months. Inexcusable!

Filed May 21, 2015 · Brakes · VA

First time brake line failed my wife was at a fast food drive thru and when leaving window applied brakes and pedal went to the floor. Two brake lines had to be replaced going to ABS module/motor pack. The next time was about a year later,had moved the truck from bottom of driveway to top and parked it. A couple of hours later brake line broke under drivers seat. Each time had to hold pedal down for 5-10 seconds to find leaking fluid. The fluid was apparently spraying on the frame and running down it. The third time another line busted. Stopped perfect at stop sign in neighborhood and when reaching the second pedal went to the floor. No warning at all three events. Brake pedal went from normal to going to the floor. There was no softness or extra travel prior to all three times. The truck now has 85,000 miles on it. My local dealers answer to why this keeps happening was it is 11 years old, maybe you should talk to sales about getting a new one. I love this truck minus the brake issues

Filed Dec 22, 2014 · Brakes · 56,400 miles · MN

Everything appeared normal when I was driving to the bank. As I was slowing to make the turn into the bank the brakes felt a little spongy. As I pulled up to the atm brakes continue to be spongy. Finished at bank and cautiously started driving home. First stop light, I had to gear down to slow to allow me to stop as the brake hit the floor. Pumping helped me stop in time to not hit the car in front of me. I should have probably called for a tow at that point, but only had back roads left to get home. Drove very slow (less than 5mph) by time home had no brakes left. Going slow enough to hit curb opposite of my driveway to stop and then backed into uphill driveway so gravity stopped me to put in park. Btw - no emergency brake to help, that is not working. Got out and a steady stream of brake fluid was coming out from under the drive side door. Looked under vehicle and saw fluid leaking from corroded (rusted) brake line between master cylinder & ABS box. Took a look at all the other line and surprised to see how corroded all of the brake lines are. I was also kind of surprised to see how horrible the entire underside, including frame, have rusted for a 10 year old truck. Definitely very upset the brake lines are that corroded and will all need to be replaced to provide confidence another one is not going to burst. I'm just very happy I didn't get in an accident and I sure hope it doesn't take someone dying for gm to issue a recall. Given the size of these vehicles and the shear damage they could do to property or human life should be a concern to gm. I'm a huge fan of gm/chevy trucks, but pending what happens may dictate my next truck. My truck has been sitting as I have not had time to try to repair myself or money available to be able to take the chance at how much a shop is going to charge.

Filed Oct 17, 2014 · Brakes · 55,286 miles · PA

I had to apply my brakes because of a sudden stop. When I did my ABS brakes worked for a second when no more brakes. Had to swerve ,to not hit car in front of me. When I stopped I was two feet past that cars right rear fender. When I looked under my truck there was brake fluid leaking from brake line above frame at drivers door. This could have been alot worse. I heard this is no the only time this has happened with this make and model of vehicle.

Filed Aug 18, 2014 · Brakes · 49,364 miles · WV

On saturday, august 11, 2012 I experienced a brake failure. After looking underneath my 2004 chevy silverado 2500hd brake fluid was dripping from a rusty brake line below the driver seat area. It appeared I lost the rear brakes so I was able to get the truck to the chevy dealership the following monday august 13, 2012. This truck only had 49,364 miles on it and was approximately 8 years old. The chevy dealer later called me with the bad news that all of the brake lines were bad and needed replaced. They also discovered the fuel lines were rusty and needed replaced too. They later notified me the calipers were rusty as they could not bleed the brakes properly so these also had to be replaced. The total of this august 21, 2012 invoice was $2,772.28 and this was with a 10% discount. Please note the rear brakes were just replaced 1207 miles earlier on april 30, 2012 for my required state vehicle inspection. During this state inspection (mileage 48,157) in april 2012 they also had to replace a speed sensor as the truck was going into ABS at low speeds. The invoice states this sensor ?came apart? And they also had to clean the other one. There is was no indication of rusty brake lines or fuel lines brought to my attention during the april 2012 state inspection and on august 11, 2012, just over three months later I experienced total rear brake failure. I certainly feel this was a sudden loss and could certainly lead to future collisions, injury or potentially death if something is not done to try to correct this brake line corrosion problem. I am thankful I was not towing a heavy trailer when this occurred and that no one got hurt but it could have been much worse. I?m glad they found the fuel line problem as this could have caused a vehicle fire or a house fire if the truck was parked in the garage if this fuel line corrosion was not corrected. Thank you for listening.

Filed May 21, 2014 · Brakes · 123,000 miles · MO

While stopped in a parking lot the brake pedal went to the floor. Closer inspection revealed that the hard brake line had burst above the fuel tank on the line that runs between the ABS module and rear axle.

Filed Nov 16, 2013 · Brakes · 113,004 miles · MD

I got in the truck to leave my house. After starting the truck and putting my foot on the brake pedal I shifted into reverse to leave my driveway. At that time the brake pedal went all the way to the floor. I was able to shift back to park as I had not release the parking brake yet. I opened the hood and the master cylinder was empty. After looking under the truck, drivers side inside frame rail, I discovered a burst brake line where it leads into the ABS module. All of the brake lines were extremely corroded and had to be replaced with stainless steel at a chevy dealer. I had the dealer perform other routine maintenance items at that time as well. They discovered that I needed to replace a chain guide in my transfer case, and repair a hole that the loose chain had caused. I find it hard to believe that chevy used stainless steel for the exhaust system, which looks great after almost 10 years, yet they used plain steel for the brake lines. I was lucky this occurred in my driveway, and not while I was towing my boat on the highway. The transfer case problem also seems like an engineering failure.

Filed Aug 2, 2013 · Brakes · 105,000 miles · MD

In driveway, started truck, applied brakes and the pedal went to the floor. Got out, saw brake fluid dripping on the pavement on left side. Saw severely (incredibly) rusted brake lines underneath. All brake lines at and near ABS module terribly rusted, nearly disintegrated. Had the failure happened while driving, an accident would surely have happened, especially if towing a trailer, which I sometimes do! I looked under my wife's toyota and see that the brake lines are all coated. Surely gm should be using coated or stainless brake lines.

Filed Apr 24, 2013 · Brakes · 55,230 miles · NY

I was towing my trailer with brakes on it and as I was stopping at a stop sign the line between master cyl and ABS unit blew out.upon inspector all the brake lines are I a very rusted condition mostly at the plastic line retainers.I am going to replace all lines to avoid a dangerous condition in the near future.

Filed Apr 21, 2013 · Brakes · 123,551 miles · PA · crash

Started vehicle in my driveway in front of garage, as I had my foot on brake, while placing transmission into drive, the brake pedal went completely down to floor, and the vehicle rolled backwards into garage door frame, causing minor damage to the aluminum flashing on the garage door frame. All attempts to pump brake pedal yielded no stopping effect. Fortunately, this episode occurred in the driveway as my intended route included a steep hill ending at a "t" intersection. Upon inspecting the vehicle, directly beneath the drivers door, there is a large puddle of brake fluid. Upon further inspection, the fluid appears to be originating from a severely rusted brake line that sits above the frame leading into the ABS controller. All the brake lines appear in the same severely rusted condition.

Filed Mar 21, 2013 · Brakes · 66,520 miles · MA

Tl* the contact owns a 2004 chevrolet k2500 (n/a) extended cab. The contact stated that while driving 25 MPH and applying the brakes, the brakes became spongy and abnormally traveled to the floorboard. The vehicle was driven to a local mechanic, who advised the contact that the brake line was corroded and caused brake fluid to leak. The mechanic repaired the brake tubing from the master cylinder to the ABS controller and also, the tubing for the two front wheels. The manufacturer was notified of the failure. The failure mileage was 66,520.

Filed Oct 5, 2012 · Brakes · 102,892 miles · CT

I was driving from the boat launch to park my 2004 chevy silverado 2500hd when the brake pedal went all the way to the floor. I pumped the brakes as I slowly approached my parking spot, however, I could not get any pressure to build up in the system. With no action on the brake calipers, I used my parking brake to stop as I entered my parking spot. There was no warning or indicator light alerting me to any brake problems. After parking I noticed a leaking brake line under the driver's side near the ABS brake module. I made a temporary repair, attempted to bleed and pump up the brakes which resulted in the rear brake line blowing out right at the hose connection. Still no warning or indicator light came on to alert me to any problems with the brake system. I had the vehicle towed home and as we were taking my vehicle off the truck, the brake warning light finally came on and the electronic dash displayed the message "service brake system". The lack of fluid in the brake reservoir must have triggered the sensor there. Upon closer inspection, I noticed that the brake line failed inside a plastic brake line retaining clip located on the outside of the frame just before it was routed over to the ABS modulator valve under the vehicle on the driver's side on the inside of the frame. I replaced all the brake lines with pre-bent stainless steel lines from classictube.com. I am only glad that this happened in a parking lot and not while I was towing my boat, I do not believe I would have had enough wits about me to use the parking brake to stop my truck. I mentioned this problem to my local gm dealer who blamed it on the treatment of roads during the winter months. Granted living in the "snow belt" one should expect corrosion but never complete brake failure without any warning. There are numerous complaints online, just search for silverado brake failure.