2003 Chevy 2500 total brake failure
 

My brother has a 2003 2500 Chevy extended cab 4X4 pickup. He was exiting off the highway last week when he hit a batch of ice on the off ramp. The ABS went off and then he suddenly lost all brakes. Yep complete brake failure!! Fortunately, he was able to downshift to slow down enough to make the turn at the end of the ramp and rolled it into an adjacent parking lot. He got out and there was brake fluid sprayed all over the bottom of the truck and a puddle of brake fluid under it.

This scares the crap out of me!

The line/lines blew out just downstream of the ABS control valve that is bolted to the drivers frame rail under the drives seat.

I'll get and post pictures of the damaged brake lines.

Therefore, if you own a Chevy/GMC truck from this period, I highly recommend that you inspect your brake lines under the drivers side for any signs of rust or damage.

Glad he's safe, YET ah begs the wild guess:

Let me guess the undercarriage looks great except for the Brake lines & Driveshaft.

Just begs for Class-Action suit huh.

I had a friend that had the exact same thing happen to him in a Dodge 2500- brake line blew on the off ramp- limped into a parking lot. I had to tow him to the garage. The boys from FAST Automotive in Indiana had a line blow on their Dodge, but weren't so lucky hit their own trailer being towed by another truck in front.

I have replace more than my share of lines on this era of Chev truck... they must have used the worst material they could find to make these lines...
always the one running to the rear... and all the lines around the ALB motor will rust and bubble up like crazy... GM should use stainless on their product... for what they cost, there should never be a HARD line failure...

What it amounts to, is, some idiot that was controlling the "bottom line", said..."Hell yeah, if it'll save 3.00 a vehicle, go with the 'China' metal...no one will ever know"... Ironically, that dude was probably hit goin thru an intersection by a guy in a 2004 Siverado with brakeline failure and pronounced DOA... hehe

I had the same problem with my 2003 GMC 2500, 2x , first time about 4 years ago. Incredible corrosion right up to the master cylinder. Also lost the AC, PS lines, and partial fuel line due to corrosion. Oil cooler lines went twice. There was an NHTSA investigation into it, but learned they all of a sudden closed the case. You'll see lots of cases on the Internet. Forget thinking you'll get some braking power, it usually happens during a sudden stop and there is almost no hydraulic pressure whatsoever. Luckily I was able to run off the road to avoid going into a tractor trailer.
Replaced my lines in stages, so I have an extra set of front SS lines if interested, but I recommend you check them all. Classic Tube makes a full set SS brake lines, they fit well. They also do fuel lines.
The way GM ignored this was pretty crappy IMO. I happily drive a Superduty now.

That is a bad spot for rust. Mine are greased by hand and a brush with waterproof grease.
Big bucks to buy all that to replace...

That's why I role around on the creeper looking at everything under the vehicle EVERY TIME i change the oil. Check it, Check it, Check it.

Yipes! I had no idea that this issue was so common.

Mike bought some stainless lines and fittings and is going to bend up his own set. He plans to cut out the bad sections and splice in new lines with compression fittings. I'm trying to talk him into replacing the whole line with stainless.

I will forward the tip about Classic Tube. Heck, I think I'll buy them and put them on for him.

He's not sue happy but if someone got hurt all options would be on the table.

Perhaps, we should tow the truck to the Chevy dealer and change the lines in the lot in front of the showroom??

I have a 2007 duramax with 55,000 miles on it. Just noticed yesterday fuel dripping underneath. Where the line leaves the tank it's all corroded. Probably a $100 line. But what does one expect for $50k. I think this is my last new vehicle.
Last summer I noticed something hanging down under the passenger side. The three 3/8 bolts rusted out at the muffler flange connection.
Also the chrome is blistering and the front and rear emblems have separated.
Did I mention the pitted forged aluminum wheels that I stripped and polished at 40,000 miles because they were out of warranty at 36,000 miles.

PS. I don't think compression fittings are legal to use on brake lines.

Yes, there should have been a recall on this and many other issues with Chevrolet trucks. The internet is littered with this problem. If Classic, The Right Stuff, Inline Tube, etc. makes replacement lines, I'll buy.
And, I believe, compression fittings are illegal too.

Huh? I have never seen a brake line that didn't use compression joints. Is this something new?

Also how many of the rusted lines are on older vehicles? It is recommended to flush brake fluid every 3-5 years especially in humid climates. DOT 4 brake fluid is so hydroscopic it can be 50% water in a couple years and rust the lines from the inside out. I just flushed my wife's 2000 Grand Am for the second time and it must've had 30% water in it and I flush the system on my Firebird every other season.

Most are made using double flare ends and unions, not compreesion fittings.

A compression fitting has a ferule that slides over the tubing and is crimped by a internally tapered nut and are definitely not legal for a brake system. A double flared fitting is legal for a brake system and is what OE fittings and lines use at the connection points.

Just a FYI, stainless is probably what should be used in a salt environment for brake line, however cost is usually the reason it isn't. Don't ever use copper tubing, while it will handle a salt environment better, it work hardens from vibration as well as not having an acceptable working pressure due to being softer than steel or stainless alloys.

Trucks are all rusty underneath BEFORE built. I saw rusty rears installed once in 2008 .

I oil them asap when I get a new vehicle

I'll be under my 05 2500 when the sun comes up tomorrow.

Pretty common failure on chevy and dodge. ford not so much that i've seen.

Installed the brake line kit from classic tube on my bosses `03 2500 HD a few months back;fit great.Beats bending all those lines from scratch.

Common on the Ford Super Duty's too Mike - I lost mine 4 or 5 years ago while going down a hill. Surprisingly, the brakes still worked sufficiently without the fluid to drive the truck to the dealership. Reminds me it's probably time to do them again. :rolleyes: