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really awful
Crashes / Fires:
12 / 0
Injuries / Deaths:
1 / 0
Average Mileage:
104,102 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 2 of 7)

« Read the previous 20 complaints

problem #112

Apr 102015

Silverado 3500 4WD 8-cyl

  • 96,100 miles


Steel brake, fuel and transmission lines are extremely rusty and failure appears to be imminent, especially on brake lines. This should be a safety recall.

- Lunenburg, MA, USA

problem #111

Feb 212015

Silverado 3500 6-cyl

  • 36,000 miles
Hi, not sure if you are aware, but there is a serious issue with 2004 Chevrolet Silverado brake lines. On 2/21/15, my son was driving my truck (VIN# [xxx]). he was about 3 miles from home when the brake pedal went all the way to the floor. I had to take the truck to an auto mechanic and he said all the lines were rusted out. One line burst, but all needed replacing. The truck only has 36,000 original miles on it. I am glad that no one was killed or injured. I am sure you are aware that this needs to be recalled by GM/Chevrolet. I did some research through the ntsb, aaa, edmunds, and motor trend and they all seem to think there is a major problem with certain years. Thank you for listening to me and thankfully, my 17 year old son knew enough to use the emergency brake to stop the vehicle. Respectfully submitted, [xxx] information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- Fort Thomas, KY, USA

problem #110

Feb 072015

Silverado 3500

  • 110,322 miles
The contact owns a 2004 Chevrolet Silverado. The contact stated that while reversing, the brake pedal was depressed but the brakes failed to respond. In addition, the ABS warning light illuminated after the failure occurred. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was 110,322.

- Orlend Park, IL, USA

problem #109

Nov 152013

Silverado 3500 4WD 8-cyl

  • 74,000 miles


I was backing out of driveway hit brake pedal and it went to the floor. Looked under truck and back left brake line had blown out upon looking at rest of brake lines they to where rusted and bulging needed to be replaced luckily happened in driveway and not in the morning when I would have been traveling down a very hilly road GM should not have used inferior brake lines.

- Nedrow, NY, USA

problem #108

Dec 172014

Silverado 3500 8-cyl

  • 171,000 miles
Driving a well maintained two wheel drive 2004 Chevrolet Silverado 2500 crew cab pickup at 30 mph on a Suburban roadway. I applied hard braking and pedal went to floor. I was able to shift automatic transmission to low 1 and apply E-brake to stop before crash. Examination of steel brake lines from master cylinder to the ABS module under the drivers floor showed excessive corrosion as reason for failure. The lines that were specifically affected travel over driver side frame rail and are out of sight for routine visual inspection. This vehicle operated in the "salt belt" (new england) and road spray from the left front tire directly impacts this area. After replacing all steel lines with stainless lines (over $500 in parts & labor) the brake system worked as designed.

- North Attleboro, MA, USA

problem #107

Dec 292014

Silverado 3500 4WD 8-cyl

  • miles
After checking the underside of my 04 Silverado 1500 4X4 for a fuel filter( which it doesn't have) I noticed the brake lines to be severely corroded. Most of the worst areas were in the bends around the frame from the master cylinder and along the frame.

- Valparaiso, IN, USA

problem #106

Dec 242014

Silverado 3500 4WD 8-cyl

  • 108,165 miles


While exiting a parking lot, I applied the brakes to stop before pulling out into traffic. The brake pedal went to the floor suddenly and with no warning. My truck went out into the road where I quickly turned hard right to avoid crossing the road. I then used the emergency brake to pull over and stop. I am a mechanic by trade, and I knew right away what had happened. My truck is in exceptional condition as I am only the second owner. The first owner had garage kept this vehicle and it has never been wrecked. I do not plow snow or off-road it. I had a GM certified mechanic fix the transfer case issue (GM also knows about this) last summer. He inspected my truck then and found nothing to be alarmed about. I did talk to him about the brake lines, to which he told me that he had to replace his in his 2004 Suburban. Two other friends of mine that both have 2004 Tahoe, had to replace their brake lines due to the exact issue. My brother-in-law has a 2006 Silverado, he replaced his lines last year, again for the same problem! this is a major safety issue and GM won't stand behind their own product? I have been a GM owner since I could drive. I won't be anymore! I am very disappointed that a recall or some type of action is not being done.

- Sykesville, MD, USA

problem #105

Dec 172014

Silverado 3500

  • 136,000 miles
Backing out my driveway I applied brakes and pedal went to the floor and saw brake fluid leaking to ground below driver side front wheel and door.

- Shelton, CT, USA

problem #104

Nov 032014

Silverado 3500 4WD 8-cyl

  • 104,000 miles
My brake pedal went to the floor due to a rusted brake line. I was able to stop but very scary. Upon inspection I realized every metal line in the truck is rusted and either already leaking or will be soon. I've had 5 Chevy trucks and never encountered anything like this with any of them. If I want to keep my truck safely on the road that I still owe $10,000 on, I am now faced with the expense of replacing every brake line, the transmission cooler lines, the engine oil cooler lines, the power steering lines, pump and cooler, and the fuel lines. This is ridiculous! Chevrolet gets good money for these trucks and they obviously messed up on this design. The rust problem with the working parts under the truck is unbelievable. I should be able to get more than 100,000 miles out of a truck that cost $40,000! I am shocked that Chevrolet put a stainless steel exhaust on this truck that will last the life of the vehicle, but the high pressure fuel lines that can cause a fire or the brake lines that could kill my family are made of inferior rust prone materials! General Motors should be ashamed and tuck their heads between their legs as they watch their loyal customers become loyal to another automaker that might have more reliable vehicles or at least stand behind their products and designs. Shame on them!

- Raymond, NH, USA

problem #103

Nov 102014

Silverado 3500

  • 46,499 miles
Was coming up to a red light and when I push on the brake pedal, it failed. Lost of brake pedal pressure. Got out and looked and there was a huge puddle of brake fluid on the road below the drivers side door.

- Garden City, MI, USA

problem #102

Nov 042014

Silverado 3500 4WD 8-cyl

  • 86,000 miles


Approaching stop sign, brake pedal went to the floor without any braking. Inspection identified corrosion through brake line tubing walls causing loss of pressure and fluid. Massive system failure occured without warning.

- Stonington, CT, USA

problem #101

Oct 252014

Silverado 3500 4WD 8-cyl

  • 176,000 miles
Out for a drive in the Pennsylvania mountains when experienced difficulty stopping. Checked brake fluid. It was 3/4 empty due to leakage in lines. Took truck to the repair shop. Brake lines need to be replaced due to rusting out. The cost will be approximately $1,000. I regularly maintain my truck.

- Folsom, NJ, USA

problem #100

Oct 062014

Silverado 3500

  • 78,000 miles
Brake line burst, very little stopping power, had to make crash avoidance maneuver, swerving off road. Upon inspection noticed all brake lines rusted badly. Will require replacement off all lines.

- White Lake , MI, USA

problem #99

Oct 262014

Silverado 3500 4WD 8-cyl

  • 192,000 miles
Was pulling a trailor with tractor and bushhog on it. 3 cars were stopped in front of me. The first one turning left. I went to stop. Brake pedal went to floor. Hitting the vehicle in front me, pushing that one into the one in front of that one. Upon inspection brake line under drivers floor had burst open due to rust. Tractor also came forward even being strapped down breaking the head gate on trailor. GM needs to step up to the plate and fix this issue with these trucks. Very lucky no one was killed or injured.

- Reva, VA, USA

problem #98

Oct 102014

Silverado 3500 4WD 8-cyl

  • 145,385 miles
Brake pedal went to the floor with very little stopping ability. Fortunately, there was time to come to a gradual stop because a quick stop was not possible. Had the vehicle towed to a Chevrolet dealer. Brake lies were "rusted through." Cost to repair was $1199.29.

- Mcmurray, PA, USA

problem #97

Oct 122014

Silverado 3500 4WD 8-cyl

  • 119,000 miles
Pulled off interstate 95 to switch drivers. When the vehicle stopped and was put into park the brake lines ruptured. On inspection lines were completely rusted (all 3). Chevrolet corporate refuses any responsibility for inferior material, dealer is charging $3400 to replace lines. Exactly 2 minutes earlier and the truck would have been on 95 and this would have been disastrous and perhaps fatal.

- Perry Hall, MD, USA

problem #96

Oct 042014

Silverado 3500 4WD 8-cyl

  • 223,000 miles
Brakes had been a little mushy, then as the driver was coming to a stop, he noticed that he lost all hydraulic pressure. He used the parking brake in order to drive it to a safe place. Looking under the vehicle the next day, the brake lines are completely rusted out and there was a puddle of brake fluid.

- Barkhamsted, CT, USA

problem #95

Sep 252014

Silverado 3500 4WD 8-cyl

  • 150,305 miles
I was pulling up to a stop sign in my 2004 Chevrolet Silverado 1500 and easing on the brakes when I noticed they were soft, so I pushed on them harder and still nothing. The brake pedal was all the way to the floor with barely any stopping power. Luckily there was no one at the stop sign and I was able to push the emergency break to get enough stopping power to come to a halt shortly into the intersection. The "service brakes" light came on once the computer noticed that the brake pedal was against the carpet and the truck wasn't slowing down, which is obviously too late. Upon further investigation, the failure seems to be in the brake lines just behind the driver side door. The plastic support bracket that supports the brake lines as they run along the frame had fluid dripping off it and rusty broken brake lines in it.

- Rumford, RI, USA

problem #94

Sep 172014

Silverado 3500

  • 76,000 miles
Wife was moving truck to garage when brake pedal went to floor; on further observation brake line had rusted to the point where reservoir was empty of fluid. We had just been hauling trailer loads of hay glad this didn't happen on open road with other vehicles involved. Bought truck new no abuse in its history. Bought 91 Chevy pickup truck new and still have that one. We have never had any problems with the brake lines on the older truck. I will definitely think twice before purchasing any more GM vehicles if they are going to put my family in danger with poor parts like this.

- Hartford, KY, USA

problem #93

Apr 082014

Silverado 3500

  • 80,000 miles
Brake lines rotted out lost brakes.

- Manhasset, NY, USA

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