NHTSA Complaint #11306239 — 2011 CHEVROLET EXPRESS 1500

WE DEVELOPED A SIGNIFICANT LEAK IN A REAR BRAKE LINE OF OUR VAN. THE LEAK DID NOT LEAD TO A LOSS OF CONTROL, BUT THE BRAKE RESERVOIR WAS NEARLY EMPTY WHEN I DISCOVERED THE ISSUE. THE LEAK WAS DISCOVERED BASED ON A LARGE SPOT LEFT ON OUR DRIVEWAY UNDER THE VAN. THE VEHICLE WAS PROBABLY DRIVEN ABOUT 50-100 MILES (ONE TO TWO DAYS) AFTER THE LEAK DEVELOPED BUT BEFORE THE ISSUE WAS DISCOVERED AND ADDRESSED. WHILE FIXING THE PROBLEM, I FOUND THAT THE LEAK WAS DUE TO AN ASSEMBLY ERROR. THE VAN'S FUEL FILLER DOWN-PIPE HAS A WORM-GEAR CLAMP THAT WAS NOT PROPERLY CLOCKED. THIS CAUSED THE CLAMP TO RUB ONE OF THE REAR BRAKE LINES AND WEAR A HOLE IN IT. I SENT TWO PICTURES SHOWING THE CLAMP AND BRAKE LINE AS I DISCOVERED THEM. I ALSO SENT A PICTURE OF THE DAMAGED LINE AFTER BEING REMOVED FROM THE VEHICLE. THE VAN HAD ABOUT 87,000 MILES WHEN THE LEAK DEVELOPED.