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 Tahoe owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact's spouse owns a 2004 Chevrolet Tahoe. The contact stated while driving approximately 35 MPH, the brake pedal was depressed and remained extended to the floorboard. The contact engaged the parking brake to bring the vehicle to a complete stop. The vehicle was driven to the residence and parked. Additionally, the contact stated that while parked, the brake pedal was depressed, and brake fluid was squirting onto the ground from underneath the front of the vehicle. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The failure mileage was 190,000.
The contact owns a 2004 Chevrolet Tahoe. The contact stated that while driving at an undisclosed speed, the brakes failed to stop the vehicle immediately while the brake pedal was being depressed. The vehicle was taken to the dealer where it was diagnosed that the failure was related to NHTSA Campaign Number: 04V045000 (Service Brakes, Hydraulic) however, the VIN was not included in the recall. The vehicle was not repaired. The manufacturer was made aware of the failure and advised the contact to file a complaint with the NHTSA Hotline. The failure mileage was approximately 150,000.
The contact owns a 2004 Chevrolet Tahoe. The contact stated that while inspecting the coils under the hood, he noticed that the master cylinder brake lines were leaking. The vehicle was taken to an independent mechanic who diagnosed that the master cylinder brake lines needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 183,500. The VIN was unavailable.
Travelling north on state route 741 with my family of 6. We began to slow for stopped traffic on a slight downhill grade. At once the brake pedal went to floor without warning and when I applied emergency brake the bracket fastening it to the frame broke as well. The truck was gaining speed without any brakes at all. I put it into a ditch doing 60 MPH. It took me 1.5 miles to finally get the truck stopped. Took it to a garage they replace all brake lines two rear calipers, master cyclinder, and hydro boost canister. How do all these parts fail at the exact same time and the emergency brake bracket break away from frame trying to stop vehicle? Apparently the size of the vehicle is to much for the emergency brake system to effectively stop this vehicle. I am told by a dealer this is a frequent issue with GM vehicle. I am very mad about this incident and putting my family at risk. …
I was traveling towards home around 45 MPH in my 2004 Chevrolet Tahoe. The car in front of me attempted a non-signaled right hand turn and then continued straight ahead. I applied my brakes in a manner to avoid hitting the car as she decided what she was going do. The pedal was firm at first, then completely went to the floor. I had no brakes at all. This resulted in me taking an off road adventure through someones yard and back onto the road to avoid slamming the car in front me as she regained her sense again. I slowly crept home and spit a trail of brake fluid along the way. The hard brake lines on this vehicle are so corroded with rust and I found the front feed line into the ABS module had burst from the corrosion and use of cheap factory lines. I could have lost my life because 11 years ago GM decided cheaper brake line material in 2004 is better than my life in 2015. …
Tl* the contact owns a 2004 Chevrolet Tahoe. While driving approximately 40 MPH and attempting to make a sudden stop, the braking system experienced a catastrophic and instant failure without warning. The vehicle did not slow down or stop, which caused the driver to crash into an embankment. A police report was filed. During the crash, the driver sustained a right knee injury that did not require medical attention. The vehicle was towed to the dealer where it was diagnosed that the cause of the failure was due to corrosion and rusted brake lines. The manufacturer was notified of the failure. The VIN was not available. The failure mileage was 160,000.
Lost brakes on highway. Got in accident. Now all brake lines have to be replaced. Never going to buy another GM piece of [redacted]. And only has 73,000 miles on it.
There is a recall #04004. "brake hydro-boost relief valve" but my VIN# is not on the list. Over 64,000 vehicles were affected and there is a "#1" on the mounting surface. All of the units detected a machining error in the relief bore cavity for modules produced from a machine identified as "fadal #1" this can and has caused my 2004 Chevrolet Tahoe to have no power assist with my steering and no power brakes. I have found myself holding two feet on the brake pedal at a red light. And can not operate in small spaces such as parking garages and certain parking stalls. I wanted to know if there is something more that I can do in regards to this particular recall and find out if there is some mistake as far as my VIN# not being recognized but yet experiencing the same problems. …
On 11-11-15 I was sitting at an atm with my foot on the brake pedal. Without warning the brake pedal went completely to the floor. Limped to our mechanic. The mechanic advised that the front brake lines were completely rusted. Replaced the front brake lines at a cost of $580. On 5-28-17 my husband had pulled into a convenience store and was letting my son out of the vehicle, had his foot on the brake and yet again, the brake pedal went all the way to the floor. Got the vehicle home, checked the brake fluid reservoir and only 2" of fluid was left, checked brake lines and found rusted out places with fluid leaking out. Got the vehicle to our mechanic, same one that replaced the front lines, he advised the same problem, rusted out lines. Estimate to replace rear lines $540. He also told me that this was a "flaw" with that year Tahoe and pick up trucks. …
Driving vehicle on local street at approximately 15mph when I attempted to stop at stop sign. Brake pedal went totally to the floor and lost all brakes. Unable to stop I narrowly missed another vehicle which was already in the intersection. Car finally came to a stop against curb on other side of intersection. Upon inspection I found that both rear brake lines had completely blown underneath drivers door. They were completely rusted through causing them to fail. When I got home I did a simple google search of this issue and found quite a few stories devoted to this problem. I don't understand how there isn't a recall on this issue. Imagine if I was going faster than 15 MPH if this event had occurred. I also have contacted GM about this problem through email.
Related recalls
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.
Brake complaints in other Tahoe years
Frequently asked questions
How common are brake problems on the 2004 Chevrolet Tahoe?
NHTSA has 86 complaints about the brakes of the 2004 Chevrolet Tahoe, 18% of the model year's 467 complaints. The component named most often is foundation components › hoses, lines/piping, and fittings (3 mentions).
Is there a recall for 2004 Chevrolet Tahoe brake problems?
Yes — NHTSA recall 04V-045 (service brakes, hydraulic, Feb 4, 2004). Recall repairs are free at authorized dealers.
At what mileage do 2004 Chevrolet Tahoe brake problems start?
Half of the complaints with a recorded mileage happened before about 105,000 miles, and 9% before 25,000 miles.
Is it dangerous?
Owners linked 12 crashes, 1 fire and 4 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.