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 Suburban owners, lightly cleaned up (personal details are redacted by NHTSA).
the brake lines rust and they burst this occurred on my main brake line going to the abs controller I had no brakes from mechanics they say this is a common problem on usa made cars brake lines should never ever rust and burst
The rear brake line failed for the second time and caused me to have accident. The issue is that the front brakes did not stop the vehicle and the brake pedal went to the floor. When this happened the first time 2009 the dealer changed the master cylinder and other brake components stating that is why the front brakes didn't work however this failure was exactly the same as the first incident absolutely no brakes.
I was on the freeway there was traffic I went to slow down my brakes locked up on me my car fish tailed I released the brakes and they were still still locked. Caused me to slid at least 30 feet I was only going 35. Which caused me slam into the center divider
When driving my 2002 Chevrolet Suburban 1500 at speeds under 10 MPH in bumper-to-bumper traffic, the ABS independently activated. This happened in dry weather on a freeway. When the ABS independently activated, the car vibrated and accelerated with difficulty and jerked. The brakes locked up, causing a tire to blow out. The car caught fire where the brakes had locked up the front right wheel. The fire commander who examined the car after putting out the fire and the mechanic who is repairing the car both explained that improper ABS activation LED to a rupture in the brake line, exposing the leaking brake fluid to the heat generated by the locked brakes. This vehicle is experiencing the same problems as indicated in NHTSA recall 05V379000 concerning the ABS system but is not included in the recall due to the VIN. …
Brakes failed while driving 60mph on highway I-476 (philadelphia pa) with the family in the vehicle. Upon braking to stop for traffic, the brake pedal went directly to the floor and pumping the pedal several times did not result in any braking of the vehicle. After managing to get the vehicle to a stop on the side of the road, and then pumping the brake pedal several more times, brake fluid could be seen coming from underneath the vehicle at both the area around the rear axle and the area under the drivers side seat. Later, inspection of the brake lines found them all to be severely rusted. After reading that this is an existing problem with GM vehicles, it is greatly disappointing, to say the least, that no notification or recall was given. Such a severe and scary safety problem should require at least notification of customers and better quality design/control of braking components.
Tl contact owns a 2002 Chevrolet Suburban. While driving between 5-10 MPH, the vehicle responded slowly when the brake pedal was depressed. The contact experienced difficulty slowing down the vehicle. The vehicle was taken to an authorized dealer, but was not repaired. The technician stated that the vehicle was previously repaired according to NHTSA campaign id number 05V379000 (service brakes, hydraulic:antilock). Also, there was a recommendation to disconnect the fuse that deactivated the anti-lock system. The recall remedy has not corrected the issue addressed in the safety defect. The failure and current mileages were 98,000. Updated 3/5/09 the consumer rear ended another vehicle at 5 MPH when he attempted to stop. Updated 03/10/09.
Began emergency breaking and evasive maneuvers. Shortly after beginning to turn, the ABS light came on and all 4 wheels locked. The result was a 180 degree spin across 5 lanes of i30 just south of downtown dallas. We almost avoided any collision, but it could have been horrible as we were close to hitting at least 7 to 10 vehicles with speed differentials of about 50mph while out of control. The failure code was the ebcm relay, and the system works if the ambient temperature is cold enough, though it fails on bumps sometime. Typical bad solder joint behavior. Many people are repairing these modules by re-soldering the relay connections.
Traveling on a 4-lane highway, 35 MPH, approaching red light in line of heavy traffic. I applied the brakes and felt the pedal go to the floor. I stepped on the emergency brake and was able to stop the truck before hitting the vehicle ahead of me. Second incident: 2014. Traveling down hill toward stop sign. Same sequence of events as above. I can't believe that chev. Suburbans sold in new england have steel brake lines! This is my 8th Suburban. First experience with rusting everywhere under chassis, ESP. Brake lines.
Driving on freeway along carpool lane when the car ahead of us stopped to move to the next lane and we all had to stop. I had a good distance from the vehicle in front of me when I hit the brakes. The brakes went all the way to the floor(literally) but still didn't stop until I crashed into the car in front of me. The ABS brakes feels unusual. I also hear a clanking sound on the differential every time I have to decelerate and go back to normal speed or just moving from "park" to "reverse" or from "neutral" to "reverse".
Brake lines rusted and brakes failed twice while driving vehicle. There were no accidents. First incident was the rear brake line burst. I replaced the rusted brake line. Front brake line burst 6 months after rear brake line was replaced. All front brake lines were so rusted, I removed and replaced all of them as a precaution. The brake lines rusted in areas where they were clamped, so that salt and dirt could not be cleaned out. Brake lines were unpainted bare steel.
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…
Brake line corrosion failure
On January 11, 2011, ODI opened EA11-001 to investigate allegations of premature brake line corrosion failure in model year (MY) 1999 through 2003 General Motors (GM) full-size pickup trucks and sport utility vehicles sold or registered in the following region of the United States that NHTSA has viewed as salt states for investigations of corrosion related issues:Connecticut, Delaware, District of Columbia,…
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 Suburban years
Frequently asked questions
How common are brake problems on the 2002 Chevrolet Suburban?
NHTSA has 127 complaints about the brakes of the 2002 Chevrolet Suburban, 44% of the model year's 286 complaints. The component named most often is antilock/traction control/electronic limited slip (42 mentions).
Is there a recall for 2002 Chevrolet Suburban 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 Suburban brake problems start?
Half of the complaints with a recorded mileage happened before about 84,000 miles, and 10% before 25,000 miles.
Is it dangerous?
Owners linked 12 crashes, 1 fire and 12 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.