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really awful
Crashes / Fires:
12 / 0
Injuries / Deaths:
1 / 0
Average Mileage:
102,995 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2004 Chevrolet Silverado 3500 brakes problems

brakes problem

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2004 Chevrolet Silverado 3500 Owner Comments (Page 3 of 7)

« Read the previous 20 complaints

problem #90

Oct 062013

Silverado 3500 8-cyl

  • 80,229 miles


I believe the original brake lines on the 2004 Chevrolet Silverado 1500 have inherent design/material flaws and are unsafe to the driving and pedestrian public. I had 2 separate instances of catastrophic loss of all braking effort on the same truck within one year of each other. On 10/6/2013 was driving said vehicle, mileage 80229, on a rural road when approaching a point of interest. Depressed brake pedal once to reduce speed to 40mph and then a 2nd time to reduce speed further. However brake pedal lost all resistance and went to the floor. Pumped brakes 4 times and no braking effort was available. Pulled parking brake which was rusted out and only provided minimal braking effort. Was able to downshift and reduce speed to eventually pull off road after approx 1/2 mile. Serviced by GM dealer, repair was "replace rusted out rear brake line and bleed" at a cost of $850. Tech inspected all other brake lines and tech found no other brake lines that had excessive rust. New brake line is an uncoated metal. On 8/19/2014 driving said vehicle, mileage 86242, about to turn onto expressway entrance ramp when traffic slowed. Depressed brake petal and pedal went to the floor; was traveling approx 15mph when brakes were lost. Fortunately I was able to Pilot vehicle away from ramp and onto shoulder. Pumped brakes over 10 times; no braking effort was applied to slow the vehicle. Parking brake again provided no braking effort. Was able to coast slightly uphill on shoulder to bring vehicle to a halt after approx 250 feet. Serviced by same GM dealer, repair was "replaced the front brake lines, to both front wheels and the four lines from the master to the bpmv. Fill and bleed the hydraulic system. Remove rusted brake bleeders and replaced" at cost of $1180. New brake lines installed are coated with a black plastic or fiber.

- Carol Stream, IL, USA

problem #89

Feb 202014

Silverado 3500

  • 96,924 miles
Truck was in don mealey Chevrolet clemont fl. 34711 for a fuel leak. Upon completion of work technician took truck out for test drive. During the ride he experienced brake failure and almost struck another vehicle. This was reported to me by the service writer [xxx]. the results were rebuild brake lines. 4000 found rear brake line from ABS unit to rear wheels leaking replace brake line and bleed brakes parts $89.71 labor $698.21 total $787.92 plus $75 haz. Fluid disposal. Information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- Frederick, MD, USA

problem #88

Aug 232014

Silverado 3500 8-cyl

  • 155,000 miles
I was launching my boat this morning and nearly launched my truck with it. Putting the boat in the water my brakes all of a sudden stopped working. Luckily I thought to put it in drive especially since I can't swim. After driving to the top of the hill I had to crash in to a bank to stop! then I noticed something leaking above the left rear tire. It appeared to be a brake line that had rusted through.".".I had my wife press the brake pedal to find where it was leaking and it was exactly what I thought. Rusted brake line! of all things designed to survive rust, the brake lines were obviously left out. This is the first time in a long time that I felt my life was in danger. After some research I learned this is very common. I just can't believe nothing is being done about it. Doesn't seem like the GM I know to put lives in danger.

- Trenton, NJ, USA

problem #87

Aug 222014

Silverado 3500 8-cyl

  • 48,000 miles


Approaching traffic light, went to apply brakes and pedal went to floor. Pulled off road and saw brake fluid from vehicle leaking. Had vehicle towed to shop, this is second time 1st time front brake line rusted through, this time the rear lines rusted through. Extremely dangerous situation.

- Califon, NJ, USA

problem #86

Aug 162014

Silverado 3500

  • 186,000 miles
The contact owns a 2004 Chevrolet Silverado. The contact stated that the brake lines were excessively corroded. The dealer stated that the brake lines needed to be replaced. The vehicle was not repaired and the manufacturer was notified. The failure mileage was 186,000.

- Waterford, MI, USA

problem #85

May 162014

Silverado 3500 8-cyl

  • 120,000 miles
While driving, I went to apply brakes at stop light when brake pedal went to floor and "service brake system" warning light came on. Was able to stop by using emergency brake. Aaa towed to local gas station and discovered that brake lines were badly rusted and had ruptured at one point. Technician ordered a brake line "kit" from GM and installed it for total cost of about $1000. After 3 months, I noticed that the brakes felt soft, and discovered it needed 3/4 can of brake fluid. Closer inspection under vehicle disclosed another badly rusted brake line located on the rear drivers side between the top of the frame & the truck bed. (it appears the bed will have to be lifted to replace this line. It either wasn't part of the kit, or the repair station skipped replacing it because it was too hard to get to.) my complaint would be that non-stainless steel brake lines were used originally, and that the lines that were installed are of inferior quality that will rust out and fail. I was able to stop the truck when mine failed because I wasn't going that fast, there were no vehicles in front of me, and it was experienced enough to apply the emergency brake. I'm not sure a younger driver going faster in traffic could stop before a collision.

- California, MD, USA

problem #84

Jul 082014

Silverado 3500

  • 117,000 miles


The contact owns a 2004 Chevrolet Silverado. While driving approximately 5 mph, the brakes failed and the service brake indicator illuminated. The vehicle was taken to an independent mechanic. The mechanic stated that the brakes needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 117,000.

- Wakefield, RI, USA

problem #83

Aug 042014

Silverado 3500 8-cyl

  • 81,812 miles
Brake lines rusted out needing replacement. Chevrolet dealership charged $772.70. Service manager says many problems. GM offers kit to replace lines. Should be recalled. Never had a brake line problem in 50 years as I maintain my vehicles. I could no long wait for a recall. The brake lines were terrible. My 2004 Subaru outback has twice the mileage and lines look like new. Brake lines should last life of the vehicle. Please do something. How can you investigate for 4 years and do nothing?

- Uniontown, PA, USA

problem #82

Jun 272014

Silverado 3500 8-cyl

  • 86,547 miles
On June 27,2014 approx. 6:30pm my brake pedal went all the way to the floor as I was backing up to turn my truck around in the driveway. I proceeded to put the truck in drive and pushed the brake again and the pedal went to the floor. I put the truck in park and got out and looked under the truck and noticed that brake fluid was pouring out from under the driver side cab. I got a closer look at what was going on and that is when I noticed that the brake line had burst. I also noticed how extremely rusty the brake lines were. The brake lines were in such bad shape from rust that repairing it was not an option. The lines needed to be completely replaced. I had the truck towed to shelor motor mile in christiansburg, va on 7/3/14. I told them to replace the brake lines because they were too rusted to repair and I did not feel safe driving it with the brake lines in such bad shape. I picked up my truck on 7/10/14 and I also got my old brake lines that was removed from the truck. After I got home I got under the truck and looked at the new brake lines and noticed they had a black coating on them. I was told that the coating was to rust proof the brake lines which the old lines did not have. I felt very fortunate that this happened while I was in my driveway and not on the highway because it could have been real bad accident.

- Pembroke, VA, USA

problem #81

Jul 192014

Silverado 3500 6-cyl

  • 115,000 miles
The brake lines collapsed leaving my truck with minimal stopping power. This has now happened two times in one month. My mechanic said there was an unexpected amount of corrosion on the lines.

- Swarthmore, PA, USA

problem #80

Jul 302014

Silverado 3500 8-cyl

  • 97,500 miles


I was traveling down the expressway about 70 mph and needed to brake quickly for road construction. When I stepped on the brake pedal, it went to the floor board and there was no pressure. The red brake light came on immediately, but there was no warning before applying the brakes. With difficulty, I was able to get the vehicle to stop and barely missed the vehicle way out in front and the road construction equipment and crew. I was scared to death.

- Cincinnati, OH, USA

problem #79

Jul 282014

Silverado 3500 8-cyl

  • 96,884 miles
I was getting ready to brake my vehicle at a stop sign, as I applied the brake pedal it went straight to the floor. Luckily I was able to apply the emergency brake to stop the truck. I only lived close by so I was able to get home without further incident. When I inspected the truck, brake fluid was all over my engine compartment and upon further inspection I could see my front driver's side steel brake line was rotted out.

- South Setauket, NY, USA

problem #78

Feb 042013

Silverado 3500 8-cyl

  • 135,247 miles
I was driving down the road and stepped on my brake pedal and it went to the floor I was told the brake lines rusted out. I had it repaired and then happened twice more. Know I had to order ss. Brake lines before my wife or someone else got killed!!!!!!!!!!!!! something needs to be done about this before someone dies.

- Arapahoe, NC, USA

problem #77

Jun 272014

Silverado 3500 4WD 8-cyl

  • 25,000 miles
The contact owns a 2004 Chevrolet Silverado 1500. The contact stated that while attempting to stop the vehicle, the brakes malfunctioned. The contact indicated that the brake pedal had to be pressed to the floor in order to stop the vehicle. After inspecting the vehicle, the contact discovered that the brake lines had ruptured causing brake fluid to spill from the vehicle. The vehicle was not diagnosed or repaired. The manufacturer was notified of the defect but no solution was offered. The failure mileage was 25,000. Updated 09/05/14 the consumer stated the vehicle was repaired. No assistance was offered from the manufacturer. The consumer stated the vehicle appears safe but, the new lines appear to be similar material from the previous defected lines. Updated 12/3/2014

- Pennsburg, PA, USA

problem #76

Jul 102012

Silverado 3500 8-cyl

  • 50,000 miles
I was driving the vehicle, , I tried to stop, and the pedal went to floor, I had the vehicle towed to a local shop. All the brake line were rusted out, I find out now GM sells a replacement kit with the line coated in ABS plastic. GM knows there is an issue with this truck.

- Ivor, VA, USA

problem #75

Jun 052013

Silverado 3500 4WD 8-cyl

  • 98,000 miles
In preparation to leave on a camping trip the next morning I attached a tag along trailer to the truck. When I pulled forward a little to test the brake and running lights on the trailer and to achieve a more level ground, so as to turn on the refrigerator, my brake pedal went to the floor and I could hear liquid leaking from under the driver's side of the truck. Upon further investigation, my mechanic replaced all the brake lines as he deemed them all unsafe due to exterior rusting. We are so glad that the brake line failure happened in the drive way and not on the interstate highway.

- Easthampton, MA, USA

problem #74

Jul 052014

Silverado 3500

  • 90,423 miles
Steel brake lines failed due to corrosion under the hood in the engine compartment and along the frame behind the driver side door. Lost the ability to stop the truck. Luckily, there was no one else on the road.

- La Crosse, WI, USA

problem #73

Jul 042014

Silverado 3500 8-cyl

  • 119,000 miles
Was driving on highway and applied brakes just before exiting on off-ramp and pedal went to the floor. Inspection of brake lines revealed that rf brake line that runs under the radiator ruptured and is severely corroded. All other brake lines having heavy corrosion as well.

- Fairfax, VA, USA

problem #72

Jun 262014

Silverado 3500

  • 96,000 miles
The contact owns a 2004 Chevrolet Silverado. The contact stated that the brake lines were completly rusted. The vehicle was taken to an independent mechanic where the technician stated that the brake lines needed to be replaced. The vehicle was repaired. The manufacturer was made aware of the failure. The failure and current mileage was 96,000. The VIN was not available.

- Peabody, MA, USA

problem #71

Jun 082014

Silverado 3500 8-cyl

  • 89,764 miles
Wife was driving my 2004 Chevy Silverado with 89764 miles when she was coming to a stop the brake pedal went right to the floor she went into other lane to avoid hitting the car in front of her. The steel brake line by the gas tank had ruptured. Seems like this is a common thing on these trucks however Chevrolet won't even acknowledge that there is an issue until someone dies. I have been a loyal GM guy for 32 years unless they acknowledge this problem and offer some kind of repair "I will never buy from GM again" and I will advise everyone I know to do the same. However I don't think they really care they will just get more money from the government when they can't sell cars.

- Wyoming, PA, USA

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