NHTSA Complaint #10625765 — 2000 CHEVROLET IMPALA

CORRODED THROUGH BRAKE LINE! I WAS DRIVING ON THE INTERSTATE AT 65 MPH AND APPLIED THE BRAKES MILDLY. MY FOOT FELT NORMAL BRAKE RESISTANCE FOR AN INSTANT AND THEN THE BRAKE PEDAL SUDDENLY WENT TO THE FLOOR. FORTUNATELY, AS MY SLOWING WAS NOT CRITICAL AT THAT MOMENT, THE FAILED BRAKING DID NOT RESULT IN A DISASTER. DURING MY DIAGNOSIS OF THE PROBLEM, ON APPLYING THE BRAKES MUCH BRAKE FLUID LEAKED ON THE GROUND BELOW THE MASTER CYLINDER, BUT NOT INVOLVING THE MASTER CYLINDER. CLOSER INSPECTION I DISCOVERED THAT THE BRAKE LINE CROSSING THE FIREWALL TO THE RIGHT FRONT WHEEL (ABOUT 12 INCHES BELOW THE MASTER CYLINDER AND A FEW INCHES TOWARD THE PASSENGER SIDE) WAS ASSEMBLED SUCH THAT IT IS EMBEDDED IN FELT (WHICH APPARENTLY PROVIDES SOUND DEADENING FROM THE ENGINE COMPARTMENT) UP AGAINST THE FIREWALL FOR ABOUT 6 INCHES. THIS FELT HOLDS WATER AND REMAINS WET ALMOST CONTINUOUSLY IN THE NORTH CAROLINA ENVIRONMENT. THERE IS EXTENSIVE RUST ON THE BRAKE LINE IN THIS AREA - AND IT IS RUSTED THROUGH, WITH BRAKE FLUID SQUIRTING OUT WHEN THE BRAKES ARE APPLIED. THIS IS VERY STUPID AND DANGEROUS DESIGN PATH FOR THIS BRAKE LINE - IT SHOULD BE INSTALLED SUCH THAT IT DOES NOT CONTACT THE FELT. IT IS OBVIOUS THAT IT WAS ASSEMBLED THIS WAY (THE LINE IS NOT FLEXIBLE AT THIS POINT) - FIRMLY FORCED UP AGAINST THE FELT ON THE FIREWALL AND HELD IN THIS POSITION BY FASTENERS - NOT DUE TO ANY MOVEMENT OF THE LINE AFTER ASSEMBLY. THIS UNNECESSARY FAILURE DUE TO STUPID DESIGN MAY WELL HAVE RESULTED IN A SERIOUS OR EVEN FATAL ACCIDENT, VERY POSSIBLY INVOLVING A PEDESTRIAN AND/OR ONE OR MORE AUTOMOBILES. ACCESS TO REPLACE THIS LINE WILL REQUIRE THE CAR TO BE ON A LIFT, WHICH I AM UNABLE TO PROVIDE, SUCH THAT I WILL HAVE TO PAY GOOD MONEY TO HAVE IT FIXED. THIS WILL MOST ASSUREDLY BE A PROBLEM (LIKELY RESULTING IS SERIOUS INJURY OR DEATH) ON OTHER 2000 ERA IMPALA'S. *TR