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really awful
Crashes / Fires:
7 / 0
Injuries / Deaths:
4 / 0
Average Mileage:
31,231 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 1 of 3)

problem #48

Apr 012015

Silverado 3500

  • miles


2004 Chevrolet Silverado. Consumer writes in regards to brake failure due to rusted brake lines. The consumer was informed when the first line of the dual system failed, the second system received additional pressure which caused that one to fail too.

- Schuylerville, NY, USA

problem #47

Apr 242012

Silverado 3500

  • 93,000 miles
The contact owns a 2004 Chevrolet Silverado. The contact was driving 35 mph when the brakes failed and the vehicle crashed into the woods. The vehicle was not destroyed and the brake warning light illuminated after the failure. The vehicle was then towed to the contact's home. The vehicle was not taken to the dealer. The manufacturer was notified. The vehicle was not repaired. The failure and current mileages were 93,000.

- Jackson, NJ, USA

problem #46

Apr 132012

Silverado 3500 8-cyl Diesel

  • 27,282 miles
Brake line rusted and failed while driving. Heavy rust on several brake lines, frame, and cross members.

- Lorton, VA, USA

problem #45

Mar 072012

Silverado 3500

  • 66,027 miles


2004 Chevrolet Silverado has severely rusted and corroded brake lines. Must be replaced. With all the emphasis on safety it is absurd that these vehicles do not have corrosion proof ( stainless steel brake lines). Repair will be very costly. I had three Ford pickups prior to this Chevrolet, kept them for a minimum of 10 years and never had a brake line problem. These are obviously inferior/defective and vehicle should be recalled and the brake lines replaced at Chevrolet's expense.

- Uniontown, PA, USA

problem #44

Dec 012010

Silverado 3500

  • 85,000 miles
The contact owns a 2004 Chevrolet Silverado. While driving approximately 15 mph, the driver depressed the brake pedal but the brakes would not respond. The vehicle eventually came to a stop after repeatedly applying the brakes. The vehicle was taken to an independent mechanic for diagnostics where the mechanic advised the contact that two of the brake lines were corroded and would have to be replaced. The vehicle was repaired but the failure later recurred. The vehicle was repaired a second time. The approximate failure mileage was 85,000.

- Wayne, NJ, USA

problem #43

Nov 112011

Silverado 3500

  • 82,301 miles
The contact owns a 2004 Chevrolet Silverado diesel. The contact stated that while the brake pedal was depressed and the gear selector was placed in drive, the vehicle emitted a loud banging noise and the brake pedal depressed to the floor. The contact inspected the vehicle and noticed brake fluid leaking and spilling over the engine. The vehicle was then towed to an authorized dealer for examination. The dealer stated that there was a power steering failure and a brake booster failure. The manufacturer was notified and a complaint was lodged. The dealer replaced the brake booster assembly and the vehicle was repaired. The failure mileage was 82,301 and the current mileage 82,600.

- Inglewood , FL, USA

problem #42

Oct 312011

Silverado 3500 8-cyl

  • 40,000 miles


Ruptured brake lines, dealer said it is very common, wants $1500 for repair. My daughter has 2003 Silverado & the day before her line ruptured also!

- Califon, NJ, USA

problem #41

Oct 172011

Silverado 3500 8-cyl

  • 54,000 miles
Brake lines rusted through casing brake failure and a crash. No warning light.

- West Milford, NJ, USA

problem #40

Sep 142011

Silverado 3500 4WD 8-cyl Diesel

  • Automatic transmission
  • 80,000 miles
The contact owns a 2004 Chevrolet Silverado. The contact stated that the brake lines failed and caused the contact to crash into a garage door while entering a residential driveway. The vehicle was taken to the dealer where the contact was advised that the brake lines were rusted completely. The failure mileage was 80,000 and the current mileage was 80,988.

- Wilcott, NY, USA

problem #39

Sep 222010

Silverado 3500 4WD 8-cyl Diesel

  • 79,400 miles
Slowing down to turn into a shopping center when the brake pedal went to the floor. I was not yet committed to the turn lane so I was able to pass the entrance and stop on the side of the road.this is the second failure the first one occurred less than 1000 miles before on 5/23/11 ODI #10402905.the service tech says the line don't look that bad, and he could not buy replacement lines from Chevrolet. I have been lucky twice!

- Mt Airy, MD, USA

problem #38

Jul 272009

Silverado 3500 8-cyl

  • 64,246 miles


I was exiting freeway and applied brakes to slow down. Pedal went to floor. Luckily I got slowed enoughtostop. Called dealer and had vehicle towed. They replaced two brake lines from master cylinder prop. Valve tobrake pressure mod. Valve. Bad design on this vehichle. Replacement parts were udated without this design. I ask about this and was informed that they did away with the original design. 30,000 dollars rolling down the road looking for an accident. They weren't interested in my safety or correcting the problem at there cost, but were glad to relieve me of $536. Thank you

- Iuka, IL, USA

problem #37

Jul 022011

Silverado 3500

  • 44,000 miles
Brake line rusted and burst

- Zion Grove, PA, USA

problem #36

Sep 012010

Silverado 3500

  • 39,620 miles
The contact owns a 2004 Chevrolet Silverado 3500. The contact was driving 70 mph when he applied the brakes and heard a loud scraping noise. The vehicle was taken to an authorized dealer where the contact was informed that all four brake pads and rotors needed to be replaced. The brake pads and rotors were replaced. The failure mileage was 39,620.

- Uniontown, PA, USA

problem #35

May 232011

Silverado 3500 4WD 8-cyl

  • 78,300 miles
I was unloading mulch from the bed of truck onto the flower beds in my yard. When I got back into the truck to move to a new spot everything was fine until I went to stop and the brake pedal went to the floor. The truck was only at an idle but the brake wouldn't even slow it down to a walking speed. The parking brake worked fine and the truck came to a stop. I put the rest of the mulching job on hold until the next day until I could figure out what had just happened and how to deal with it. The next day I checked the brake fluid and added almost a quart. When I went to move the truck the brake still went to the floor but I was ready for that and got the truck off of the grass and back out onto the driveway. That was when I saw just how bad it was leaking brake fluid and the truck is still here at my house. I guess I will have it towed somewhere to have the brake line that runs down the left side of the truck to the rear wheels replaced.

- Mt. Airy, MD, USA

problem #34

Apr 272011

Silverado 3500

  • 62,000 miles
Brake rotors deteriorated to put they had to be replaced, could not be resurfaced. Found many other people have had same problem. Seems to me GM has used inferior metal. Truck is used only for occasional hauling. Truck is 2 wheel drive - no off roading.

- Wilmington, DE, USA

problem #33

Apr 162011

Silverado 3500

  • 70,510 miles
My wife and I were traveling down a steep hill with a stop sign at the bottom. I proceeded to begin pumping the brakes to slow down, as I was pumping the brake, the pedal kept going down further and further to the floor. It went all the way to the floor and a red warning light came on telling me to service the brake system. I used the emergency brake at the last minute to come to a complete halt. I got out and noticed some oil on the pavement that turned out to be brake fluid. I stopped at an auto place and bought a large bottle of brake fluid to fill the master cylinder. I then stepped on the brake and could see the fluid spewing out of one of the brake lines. The brake lines are very badly corroded. I towed the vehicle to my neighborhood mechanic and he informed me that another Chevy truck was there with the same problem. This near miss truly scared both me and my wife and we were both grateful we didn't have a serious crash. The vehicle is now at a Chevy dealer for repair and they will be starting the work on Thursday, April 21st. I did contact GM to complain about what I believe is a very serious safety issue, they have called me to ask for the details. I've researched this problem online and found that there are numerous Chevy truck vehicles with the same corroded brake lines so I decided to put in a complaint. The NHTSA has complaint #ODI 10358067 already in it's database and I suspect many others based on what I see online. Chevy brakes systems have 365 complaints noted at And I question how many have not been reported. Just a note, I am an ex-engineer and believe the design is very poor and that the material chosen actually begs for failure. GM engineers should be ashamed of the design. Please contact me if you have questions. Thank you.

- Vestal, NY, USA

problem #32

Jan 192011

Silverado 3500 8-cyl

  • 40,000 miles
Brake lines, transmission lines and engine coolant lines all failing on 2004 Chevy Silverado 3500 hd as well as on 2003 GMC Sierra 2500 hd. These problems have caused numerous amounts of time to repair and replafe, and today there was a brake failuer on the 2004 hd GMC that almost resulted in deadly accident. These lines should not have rusted and we have issues with both vehicles on the same lines. These vehicles were producted with inadequate parts for all lines on the underside of vehicle. There should not be 1,000 plus complaints from consumers regarding the rusting of these components, of which have cuased several major anmd life safety issues. The brake lines are an integral part of any vehicle and to have them rust thru to the degree of all the complaints there is obviously an issue with the compenents the manufacturer installed on these vehicles. Between our 2004 Chevy and 2003 GMC trucks we have replaced all of the tranmission collant lines, oil engine lines and ready to change brake lines in 1 truck with the other truck having to also be replaced due to rust. The entire underside compenents are completely rusted through.

- Mokena, IL, USA

problem #31

Nov 152006

Silverado 3500

  • miles
The contact owns a 2004 Chevrolet Silverado. The contact stated that while driving at various speeds with the brakes applied they extended to the floor and the vehicle failed to come to a complete stop. The dealer was informed about the failure and stated that they could not find anything wrong with the vehicle. The vehicle was not repaired. The failure mileage was unknown. The VIN was not available. The current mileage was 70000.

- Dover , NJ, USA

problem #30

Sep 152010

Silverado 3500

  • 42,000 miles
2004 Chevrolet Silverado. When decelerating to stop for a red light, the ABS system activated causing the vehicles deceleration to decrease, thus increasing the stopping distance, resulting in a near collision. The vehicle now does this consistently during every stop once the vehicles speed drops bellow 10 mph. There are no warning lights indicating anything is wrong with the vehicle, which is even more alarming. This problem seems to be identical to that in NHTSA campaign id number 05V379000. If there is an problem with speed sensing (as in NHTSA campaign id number: 05V379000), the system should be able to detect inconsistent sensor readings and render the ABS system into a passive mode as a fail safe measure.

- Shafer, MN, USA

problem #29

Mar 012010

Silverado 3500

  • 79,000 miles
The contact owns a 2004 Chevrolet Silverado 2500 hd. The contact stated while driving at approximately 40 mph and applying the brakes, the brakes were hesitant to engage. He had to depress the brake pedal into the floorboard in order to bring the vehicle to a stop. The vehicle was taken to an independent mechanic but the failure could not be duplicated. The dealer advised there were no recalls on the vehicle. The failure mileage was 79,000 and the current mileage was 80,000.

- Bakersfield, CA, USA

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