NHTSA Complaint #11425347 — 2005 CHEVROLET SILVERADO 1500

As I approached an intersection to make a left-hand turn, I stepped on my trucks brake pedal. I experienced a complete loss of braking power, with the trucks brake pedal going straight to the floor, after an instant of a firm, solid pedal. Pumped the pedal to try to regain brake operation to no avail. No hydraulic pressure was present. No warning lights or other indications of brake system failure occurred. Truck was driven home a very short distance using e-brake. Brake fluid was seen dripping from the rear axle area in large amounts. Truck was towed to my local garage which found a burst steel brake line at the junction with the rear hydraulic flex hose. Other brake lines were heavily rusted. Rest of the undercarriage was not similarly rust like the brake lines. The garage stated this was not the first Silverado they saw with this problem. All steel lines were replaced with stainless steel lines, and as a precaution we replaced all brake hoses as well. The bleeder screws on the front disk brake calipers, and on the rear wheel cylinders were also found heavily rusted and frozen, so those components were replaced as well. The shop stated this issue of severe corrosion of brake lines and bleeders is very common on this generation of Silverado’s . They have repaired quite a few like mine after similar brake failures. If you research the issue on-line, there certainly is a problem with these trucks. In my 45 years as a mechanic and practicing mechanical engineer, I have never seen brake system components so severely corroded as the ones removed from my truck. I was lucky I wasn’t towing anything, or was at highway speed when the failure occurred. The next owner may not be that lucky if it happens to them.