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 2004 Chevrolet Silverado 2500 owners, lightly cleaned up (personal details are redacted by NHTSA).
On 4/28/2016 traveling to work following a tractor trailer in a 55 MPH zone, the tractor trailer abruptly merged into the right turn lane after a curve without a signal leaving two stopped cars in my travel lane making a left turn. I applied hard pressure to my brakes and the pedal went to the floor. I impacted an avalanche that was pushed into a small compact car causing substantial damage to my vehicle and the avalanche. The driver of the avalanche was transported to the hospital with minor injuries. While at the accident scene I noticed fluid leaking under my truck just behind the left rear tire. The truck was towed from the scene to a body shop where they discovered 2 ruptured brake lines in between the master cylinder and proportioning valve. Attached pictures show severally rusted brake lines with no other rust or corrosion on parts in the surrounding area. …
While traveling 50 MPH towing a boat applied the brakes , the vehicle slowed down and the brake pedal went to the floor with the units finally stopping . All brake failure warning lights light up on the dash and upon inspection it was discovered the brake line to the right front wheel had rusted through and blew out all the brake fluid directly under the drivers door. All remaining brake lines are severely rusted and appear swollen as to be ready to burst as well under the drivers door along the frame rail. Vehicle has 2,760 engine running hours on it with 82,500 miles driven. All brake lines are original to the truck .dealer estimate to replace all brake lines was in excess of $2,000. This vehicle is only driven on the highway and never off road. …
While driving I saw a deer, it started toward the road I was traveling at 50mph the deer started to run to cross my path. I applied my brakes (I should have stopped in plenty of time but....) the pedal went down approximately halfway as normal and held firm, then the pedal continued to the floor, the brakes no longer slowed my truck impacting the deer. A similar incident happened two weeks prior. The first time the left rear brake line failed over the fuel tank. The instant incident the left front brake line failed two inches from the wheel flexible brake line joint. An automobile that is 9 years old should not have brake lines failing, this vehicle has just recently rolled over 100,000 miles mark and is used to pull the family rvs it is not a daily driver. Why is steel used for brake lines? It rusts! Why is it not coated? Why not stainless steel? …
Returning home, I proceeded to back into my driveway, I applied the brakes to reverse into the driveway and the brake pedal went to the floor. Very minimal if any brake force was left to stop my truck. I got it back into the driveway, got out and brake fluid was dripping on the ground under the front part of the truck. I determined the fluid was coming from a brake line. I called for a flat bed wrecker, took it to tuffy auto centers at 11524 n saginaw st clio mi. They told me that these brake lines are known to corrode out, and needed to be replaced. I paid to have all brake components inspected and all lines replaced. The cost for parts and labor to me was $531.58. My aaa membership paid for the wrecker. I did not know this was a very common problem known to GM, and that it should have been addressed. I feel this could have been a very bad accident. …
I have had a complete brake job because all of the lines rusted out and failed as I was driving. Fortunately, I was able to use the emergency brake to stop safely. I spent rough.y $3,000 to get this repaired. Now the fuel lines, fuel cooler and everything attached has rusted out to the point that it is going to be an additiona $2,500 to repair this. Also, the complete under carriage and rear end has rusted to the point that I am expecting it to fail at any time. This is not only a dangerous situation, but is extremely costly to the consumer, me. When the brakes failed, I was driving on a street approaching a busy intersection. With no warning at all, the pedal went to the floor and I had no brakes. The repair facility mechanic said he has never seen a system so bad. I keep the vehicle in a garage and have washed the under carriage in the winter to keep road salt from accumulating.
Was entering drive-thru restaurant, gave order, proceeded to window to receive order/pay. Noticed that upon stopping at window, brake pedal started to depress normally, and then went all the way to floor. Within a few seconds smoke started coming into driver compartment thru air vents, smoke could be seen coming out of engine from under hood. Quickly proceeded to move vehicle to empty parking spot/area.turned vehicle off, extinguished fire burning in engine compartment. Brake line burst sending brake fluid onto exhaust manifolds igniting engine compartment insulation. Could have been a serious incident/fatality of my 5 year old daughter and myself and/or others if traveling at speed and/or not able to extinguish fire quickly. This is an engineering defect with a high potential to cause fatalities/injury that needs to be addressed by the manufacturer.
Started vehicle in my driveway in front of garage, as I had my foot on brake, while placing transmission into drive, the brake pedal went completely down to floor, and the vehicle rolled backwards into garage door frame, causing minor damage to the aluminum flashing on the garage door frame. All attempts to pump brake pedal yielded no stopping effect. Fortunately, this episode occurred in the driveway as my intended route included a steep hill ending at a "t" intersection. Upon inspecting the vehicle, directly beneath the drivers door, there is a large puddle of brake fluid. Upon further inspection, the fluid appears to be originating from a severely rusted brake line that sits above the frame leading into the ABS controller. All the brake lines appear in the same severely rusted condition.
I was traveling home from dropping my dog off at his groomer. I went to brake coming to an intersection to prepare for a change in the light when the brake pedal went straight down to the floor with no warning light in the gauges or information system until after the incident happened. I had very little braking at all and was able to get the truck to my resident without incident. I had the truck towed to a mechanic who informed me the brake line had rusted completely through. I have read many complaints being filed by other Chevy Silverado owners. When is GM going to be held responsible for failing parts on all of their vehicles? I was a lucky individual that it was early morning and very lite traffic on the road I was traveling.
Brakes failed under hard stop (highway, in motion) to avoid a collision with deer. Master cylinder to ABS module steel brake line failed in a mode of rupture due to corrosion. All other steel lines were corroded and contacted GM. 2 other Silverado line vehicles owned also failed this year due to corrosion. GM response was that no recall existed. Replaced all steel brake lines in vehicle with stainless aftermarket lines. After multiple contacts with GM customer service, I was told to save my receipts for repairs. This is an incorrect material specification, latent defect and GM needs to be held accountable. 3 vehicles that I own with the same repair in 8 months. Inexcusable!
Coming out of my driveway, which is approximately 1200 feet long, I hit the brake pedal which went straight to the floor, without even slowing the truck from 15 MPH (it is very slightly downhill near the very end). I crossed the road and was hit by an oncoming vehicle approaching my driveway. Fortunately, the vehicle was a friend slowing to enter my driveway and the collision was minor. Destroyed my rear bumper and damaged the left rear quarter panel. Had the oncoming vehicle been traveling at a normal rate of speed for this road, it would have been much worse. Likely with injuries. It is a rural road with a 35 MPH speed limit and people generally drive it at 40-45 MPH.
Brake complaints in other Silverado 2500 years
Frequently asked questions
How common are brake problems on the 2004 Chevrolet Silverado 2500?
NHTSA has 168 complaints about the brakes of the 2004 Chevrolet Silverado 2500, 46% of the model year's 368 complaints. The component named most often is foundation components › hoses, lines/piping, and fittings (10 mentions).
Is there a recall for 2004 Chevrolet Silverado 2500 brake problems?
No. NHTSA lists no brakes recall for the 2004 Chevrolet Silverado 2500. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 Chevrolet Silverado 2500 brake problems start?
Half of the complaints with a recorded mileage happened before about 80,000 miles, and 8% before 25,000 miles.
Is it dangerous?
Owners linked 12 crashes, 1 fire and 5 injuries 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.