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 owners, lightly cleaned up (personal details are redacted by NHTSA).
Tl* the contact owns a 2004 Chevrolet Silverado. The contact stated that while driving at approximately 30 MPH, the brakes suddenly failed and the driver lost control of the vehicle. As a result, the contact crashed into a ditch. The contact indicated that when depressing the brake pedal, it extended to the floorboard. The independent mechanic examined the vehicle and discovered that brake lines had rusted. The contact also discovered that the frame, the rocker panels and the tailgate hinges had also rusted. The manufacturer was notified of the failure. The failure mileage was 113,000. The VIN was not available.
While exiting of a highway and traveling 25 MPH my brakes completely failed. I pushed the pedal to the floor several times but it did not slow the truck. As a result I rear ended a vehicle in front of me. I had now warning or check light for the brakes previous or since. Upon inspection I discovered corroded and leaking brake lines in the middle section of my truck.
I had the following problem with my 1999 Silverado as well: while driving my 2004 Silverado down rt. 128 in ma. At rate of speed of about 45 MPH the person in front of me approximately 75 feet (?) stopped suddenly. There was plenty of distance to stop. If I was driving my 1968 Dodge dart with 1 brake and bald tires I could have stopped. However, while driving the 2004 modern computer controlled vehicle, the truck failed to stop and I rear-ended the driver in front of me. The air bag was not deployed because of the slow rate of speed. The reason the truck failed is because ABS would not stop the tires because the road was rough like a wash board. The truck just kept rolling forward at a slow rate and I could not turn off due to the guardrail and traffic to my right. I watched my new truck slowly hit the person in front of me. They were driving a Nissan that just got a scratch on it. …
I just found this web site and saw that a lot of people were having the same issue with their brake lines popping. In my case I was backing up to hook up my 24ft boat and trailer. While I was getting my truck in position to hook up the trailer I noticed that my brakes were getting softer and softer very quickly. After pumping the brakes and realizing that I was not stopping I ended up hitting the trailer with the back of my truck. Once I got of my truck I noticed there was brake fluid all over the under carriage of the truck and tire. I was very very lucky that this happened in my driveway. I was about to go on a 300 mile trip towing a boat on the highway. With this happening it pretty much ruined a family vacation that we had planned for some time to take the boat. With the brake lines breaking I was unable to use my truck to pull my boat. …
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# [redacted]). 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, [redacted]
Dt: the contact stated that 2004 Chevrolet Silverado failed to stop and crashed into another vehicle. The speed was around 40 MPH when the driver went to apply the brakes and the ABS did not engage. The brake pedal went completely to the floor. The contact was standing up in the vehicle and mashed the brake to the floor. There was plenty time to stop, but the contact's vehicle went sliding into another vehicle. This created a chain reaction with other vehicles. The total of number of vehicle involved in the accident were four. Neither the dealership nor the manufacturer were contacted about the brake failure. A police report was taken. There is a picture of the front end of the drivers vehicle. The problem with the brakes was intermittent. The vehicle has not been checked for the brake problem by a dealership or independent party. The property damage did affect three other vehicles. …
I was driving along and had to hit the brakes immediately. I almost hit the car in front of me. I noticed I had to start putting the brakes all the way to the floor in order to stop, especially on an incline. The brake light went on and off a few times so I took it to a shop to have it looked at. They told me that my brake line blew and all the other brake lines are rusted and the truck is not safe to drive. This truck is only 11 years old, that is absolutely unacceptable that all the brake lines are rusted. The truck only has 108K miles. I called a local Chevy dealership and they quoted me 3K+ to fix it. It involved at least 20 hours of labor and they needed to lift the frame off to fix. I can not believe their are no recalls from GM or atleast them offering any help to pay for this. The dealer did not offer me any help or remedy to the situation, just wanted me to fork up 3K.
My brother inlaw owns a 2003 GMC sierra and experienced total brake failure due to corroded brake lines in 2009. Upon inspecting my brake lines on my 2004 Silverado I observed the the brake lines were corroded and would have to be replaced before they failed as well. My truck was only 5 years old at the time! After much discussion with the dealership where I purchased this vehicle I determined that they would not stand behind their product and had to pay out of pocket for the repairs. I still have the corroded brake lines, receipt and pictures of lines on truck before replacement. Keeping all evidence in case of recall. By the way, my exhaust system looks like brand new. Why didn't they use the same material for the brake lines? I don't expect anything to be done about this until cnn starts running stories about people getting killed by this problem!
I was launching my boat this morning and nearly launched my truck with it. Putting the boat in the water my brakes all of a sudden stopped working. Luckily I thought to put it in drive especially since I can't swim. After driving to the top of the hill I had to crash in to a bank to stop! Then I noticed something leaking above the left rear tire. It appeared to be a brake line that had rusted through.?.?.I had my wife press the brake pedal to find where it was leaking and it was exactly what I thought. Rusted brake line! Of all things designed to survive rust, the brake lines were obviously left out. This is the first time in a long time that I felt my life was in danger. After some research I learned this is very common. I just can't believe nothing is being done about it. Doesn't seem like the GM I know to put lives in danger.
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 $500.00 in parts & labor) the brake system worked as designed.
Related recalls
Parking brake
On certain pickup trucks equipped with manual transmissions and built with either pbr parking brake systems or trw parking brake systems, the parking brake friction linings May wear to an extent where the parking brake can become ineffective in immobilizing a parked vehicle.
Remedy: Dealers will install a low-force spring clip retainer for vehicles equipped with a pbr parking brake system. On vehicles equipped with the trw parking brake system, dealers will install a redesigned parking brake cable…
Service brakes, hydraulic
Certain trucks, sport utility vehicles, and vans equipped with Bosch hydro-boost brake assemblies, the hydraulic brake booster pressure accumulator May crack and separate from the hydro-boost assembly during normal operating conditions.
Remedy: Dealers will test the hydro-boost assembly for functional operation of the two-function valve. If the hydro-boost assembly fails the test, dealers will replace the assembly free of charge.
Service brakes, hydraulic
Certain sport utility vehicles, pickup trucks, and passenger vans fail to comply with the requirements of federal motor vehicle safety standard no. 135, ?passenger car brake systems.? Some of these vehicles were produced with an out-of-specification brake hydro-boost housing relief valve bore.
Remedy: Dealers are to replace the hydro-boost relief valve. The recall began on June 18, 2004. Owners should contact Cadillac at 1-866-982-2339; Chevrolet at 1-800-630-2438; GMC at 1-866-996-9463; or Hummer at 1-866-486-6376.
NHTSA investigations
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.
Brake complaints in other Silverado years
Frequently asked questions
How common are brake problems on the 2004 Chevrolet Silverado?
NHTSA has 211 complaints about the brakes of the 2004 Chevrolet Silverado, 34% of the model year's 622 complaints. The component named most often is antilock/traction control/electronic limited slip (27 mentions).
Is there a recall for 2004 Chevrolet Silverado brake problems?
Yes — NHTSA recall 05V-161 (parking brake, Apr 22, 2005); NHTSA recall 05V-043 (service brakes, hydraulic, Feb 8, 2005); NHTSA recall 04V-045 (service brakes, hydraulic, Feb 4, 2004). Recall repairs are free at authorized dealers.
At what mileage do 2004 Chevrolet Silverado brake problems start?
Half of the complaints with a recorded mileage happened before about 68,000 miles, and 22% before 25,000 miles.
Is it dangerous?
Owners linked 31 crashes, 0 fires and 12 injuries and 2 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.