Which parts fail
Components named in complaints (service brakes, ABS, rotors and pads, parking brake).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2002 Chevrolet Avalanche owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2002 Chevrolet Avalanche. The contact stated that while driving at an undisclosed speed, the ABS and oil warning lights illuminated. Additionally, the speedometer, the 4-wheel drive function, parking brake, and headlights failed to operate as needed. The instrument panel light failed to illuminate, the gear shifter did not display the selected gear, the sub-frame was corroded, and the wheel hub bearing assembly was fractured. The vehicle was not diagnosed nor repaired by an independent mechanic or dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 142,000.
The contact owns a 2002 Chevrolet Avalanche. The contact stated while attempting to stop the vehicle, the brake pedal was firm, and vehicle kept accelerating unintendedly. Several warning lights were illuminated. The vehicle was taken to an independent mechanic to be diagnosed. The contact was informed that the failure was due to a faulty ABS module. The vehicle had not been repaired. The manufacturer was made aware of the failure and determined that the vehicle was not included in a recall because he was not located in a salt State. The failure mileage was unknown.
Tl* - the contact called stating that he took 2002 Chevrolet Avalanche 1500 to the dealership on 09/29/05 for wheel inspection, at the time the vehicle's odometer read 59,289 miles. An inspection was done with invoice stating wheel sensor and inc. Cleaning was done. The contact stated that he felt that they didn't apply zinc/x to the sensor during inspection. The vehicle malfunctioned on 11/13/06 while he was pulling into the driveway and the vehicle didn't stop once the brakes were applied. The contact stated the vehicle damaged the garage door. The contact took the vehicle back to dealership on the next day, and was shown that the wheel speed sensor was not in its proper place and it was rusted. The dealership told the contact that the rear wheel brake dust covers were rusted and they needed to be repaired before they would fix the problem. Also, he was having brake problems. …
Brake lines are made out of defective materials GM knows they have a problem the lines rust out prematurely . The first one blew out I was backing in a parking space pedal went to the floor. The second one blew at a traffic light pushed on the brake went thru the red light dodged traffic .the third on the interstate traffic was stopping suddenly pushed on the pedal another brake line broke went to the floor and I managed to hit the median cross the middle and get it stopped before a head on collision with the traffic heading the other direction on interstate 81 . The rest of the under side is rust and corrosion free only the brake lines are rusted out ! .that being said GM has a repair kit with coated lines they always have in stock because they know its a major problem !!! I got a repair estimate from my local dealership $1580.00 I am replacing all steel lines . …
About 2 months ago, I had a low-speed collision in heavy traffic. At about 15-20 MPH I braked hard, and the anti-lock brakes kicked in, but did not stop in the usual distance. I hit the vehicle in front of me. No damage or injuries, but very disconcerting. I read about the recall on the ABS systems of these vehicles, and took it to the dealer toady to have it performed. I was told my VIN was not on the recall list, and did not qualify. I'm having the work done anyway, at my expense. I also just failed my first nj state inspection due to the emergency brake not holding. The brake has never been used. I also see a recall on this class of vehicle (k2500)for this item, and asked the dealer to perform this recall. I was told again this VIN was not on the recall list. Again, I am having this work done at my expense. Thank you.
I went off road at 45 MPH airborn struck a very large tree which caused vehicle to roll over violently landing on its top. No air bags deployed, both my wife and I were ejected from the seat belts OnStar was not notified. I noticed brakes acting strange just before leaving the road, they didn't slow the vehicle and didn't "click" like antilock breaks should. Vehicle was a total loss, windshield and drivers window broke, severe buckling of hood, passenger side pushed back to the tire, frame torn in several areas, duct and lower dash area displaced, sdm was downloaded showing incomplete data, sdm data does not support the amount of damage and know facts. My wife had to be airlifted to trauma cntr with serious injuries, my injuries were put on hold so that I could be with her.
While driving my truck and towing a trailer, I lost almost all my braking power. Had to down shift and use the emergency brake to stop. Found that a brake line from the master cylinder to the anti-lock brake module (which is mounted under the drivers seat, great place) had rusted through and blew out. Found all the brake lines are severely corroded in this area and need to be replaced. Looks like GM used inferior metal brake lines in constructing the vehicle and located the anti-lock brake module in an area that gets severe exposure to the elements. The vehicle was totally rendered unsafe with the rupture of one brake line, which indicates the system as a whole is a faulty design. I was very luck to have been able to stop and not hit another vehicle.
Tl* the contact owns a 2002 Chevrolet Avalanche. The contact stated while driving, the ABS lamp illuminated. When he tried to engage the brakes the vehicle did not stop in time, as a result he rear ended another vehicle. A police report was filed and no injuries were reported. The vehicle was taken to a local mechanic who diagnosed that the ABS module was defective and needed to be replaced. He took the vehicle to a dealer who confirmed the failure. The manufacturer was made aware of the failure and did not offer any assistance since the vehicle was not included in recall NHTSA campaign id number: 05V379000 ( service brakes, hydraulic:anti lock). The vehicle was not repaired. The failure mileage was 90,000 and the current mileage was 114,000.
This is second failure of brake line. No indication other than severe rust under vehicle. Loss of stiffness in pedal when attempt to brake down hill in snow/ice. Brake light came on , needed to use transmission to control speed. Vehicle did sustain damage when unable to control speed enough it crashed into a structure. This also caused damage to structure. No injuries because most people in vehicle were able to get out. This vehicle has had both wheel sensors fail and entire hub assembly fail. The brake line has failed at about 40,000 miles but was covered by warranty by manufacture. No injuries at that time because of experienced driver behind the wheel as well as this incident as reported.
I am entering this in regards to your investigation pe05020. This is on an incorrect activation of the anti-lock brake system in Chevy trucks 99-2002. I believe my vehicle has this defect and it May have contributed to two accidents. The defect is in the anti lock brake speed sensor and occurs due to corrosion. My family has a snow removal business so I frequently use the truck in bad weather..also I lived across the street from the ocean for a year so the truck was frequently exposed to salt spray. I would be happy to let you examine the truck if you would like. I have not gone to Chevy to request repair yet..awaiting advice from my insurance company.
Related recalls
Service brakes, hydraulic › Antilock/traction control/electronic limited slip
Certain pickup trucks and sport utility vehicles May experience unwanted antilock brake system (ABS) activation. This condition is more likely to occur in environmentally corrosive areas.
Remedy: Dealers are to remove the wheel speed sensor and thoroughly clean the wheel speed sensor mounting surface on the bearing, apply rust inhibitor to the cleaned surface, grease the mounting surface, reinstall the wheel…
NHTSA investigations
Brake line corrosion failure
The Office of Defects Investigation (ODI) received Defect Petition DP10-003 on March 2, 2010, requesting the investigation of model year (MY) 2003 Chevrolet Silverado 2500HD 4WD pickup trucks for corrosion failures of the vehicle brake lines.DP10-003 was granted and on March 30, 2010, Preliminary Evaluation PE10-010 was opened on more than six million model year 1999 through 2003 light trucks and sport utility…
Unwanted low-speed ABS activation
In a letter dated August 29, 2005, GM notified odi that it was recalling certain model year 1999 through 2002 c/k pickup trucks and sport utility vehicles to correct a problem with anti-lock brake system (ABS) wheel speed sensor corrosion that May result in unwanted ABS activation and extended stopping distances during low-speed braking (recall 05v-379).GM's recall covers approximately 804,000 vehicles currently…
Hydraulic pump failres
GM is conducting a recall on all subject vehicles build between May 1999 and October 14, 1999.significant changes were incorporated into production in early October 1999, and vehicles built after that date have lower warranty failure rates.the complaint and warranty data appear to support the effectiveness of these changes.
Parking brake failure
Odi's review of complaint data received since the close of ea04-011 revealed no indication that the investigation should be re-opened.more details can be found in the federal register notice enclosed in the dp05-009 public file.odi reserves the right to reopen the investigation in the future should conditions warrant.
Brake complaints in other Avalanche years
Frequently asked questions
How common are brake problems on the 2002 Chevrolet Avalanche?
NHTSA has 200 complaints about the brakes of the 2002 Chevrolet Avalanche, 45% of the model year's 444 complaints. The component named most often is antilock/traction control/electronic limited slip (46 mentions).
Is there a recall for 2002 Chevrolet Avalanche brake problems?
Yes — NHTSA recall 05V-379 (antilock/traction control/electronic limited slip, Aug 29, 2005). Recall repairs are free at authorized dealers.
At what mileage do 2002 Chevrolet Avalanche brake problems start?
Half of the complaints with a recorded mileage happened before about 71,000 miles, and 19% before 25,000 miles.
Is it dangerous?
Owners linked 18 crashes, 0 fires and 6 injuries and 3 deaths to brakes problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.