Rusting Metal Brakes Lines Causing Sudden Brake Failure

After everything else fails they say contact your Congressman. Well below is my complaint I sent to him (Chris Carney - Pa.).

THE PROBLEM: Sudden and unexpected vehicle brake failure due to a burst metal brake line that rusted through.

SUMMARY: I experienced sudden and total brake failure on 5-15-09 due to a burst metal brake line on my 2004 Chevy Avalanche with only 38,916 miles on it. My brake pedal went all the way to the floor. Fortunately the line burst on a level and quiet residential Clarks Summit street and I was able to bring my vehicle to a slow and safe stop. Examination revealed all the brake lines under the drivers side door were severely rusted and rotted and gushing brake fluid. A GM Dealership replaced all the brake lines to the front brakes, to the master cylinder, to the ABS Control Module plus the rear backing plates were replaced due to severe rust. Also, the right rear caliper replaced due to severe rust. Total cost of repairs $1,382.52.

MY CONCERN - WHY I AM WRITING YOU - It's not about the money. This is the 3rd GM vehicle I have owned where I encountered a sudden and unexpected brake failure due to brake lines rusting to the point of failure and requiring replacement of multiple metal brake lines. Previous vehicles include a 1999 Buick Regal (purchased new) failing on 9-2-2003 at 30,574 miles and a 1999 Buick LaSabre failing 5-19-2009 at 145,304 miles. GM has denied assistance of any type in the case of my 04 Avalanche and 99 Buick Regal. The 99 LaSabre was self repaired.

These are not isolated incidents for vehicles driven in snow belt states and Canada, as reported on various automotive blogs and forums. I think this is the tip of the iceberg. You would think that the most important safety feature in a vehicle would be the last to fail and one has to wonder why the sheet metal rust through warranty (6 years or 100,000 miles) doesn't apply to critical components such as brake lines. Why aren't metal brake lines made of material that resists rust such as Teflon coated steel, stainless steel, or a galvanized material? Clearly, GM is not answering these questions.

I believe we are only seeing only the tip of the iceberg of rusting brake lines failures. The NHTSA won't publish numbers (nor will GM). So obtaining the actual nationwide numbers of brake line failures, and resulting accidents and injuries are hard to come by. Not everyone enters complaints into the NHTSA database, even if they know the NHTSA exists. Insurance companies and repair shops provide no records. Nevertheless, GM cars in particular, in the snow belt states, seem to be most susceptible to rusting/rotting/failing brake lines. My repair shop tells me they are constantly replacing rusted brake lines. A few months ago the local news reported an accident (in Scranton) involving a late 90's Cadillac that ran up on a sidewalk. Reason for crash, per the state police, was brake line failure. I also personally know others who have had their GM brake lines rust out.

Pa. state inspections only measure rotor/brake pad/drum/shoe thickness. Metal brake lines are NOT part of the inspection for significant rust and corrosion and unless there is an obvious brake fluid leak, the vehicle will pass. Nevertheless, there is no reason brakes lines should rust through to the point of failure for the life of the vehicle.

INSULT TO INJURY CATEGORY - On 9/16/09 the CSPC (yes - I know the CSPC doesn't do vehicles) recalled garlic presses (Release 09-343) because the blades can break during use, posing a laceration hazard to users. Garlic presses versus bursting brake lines? What's wrong with this picture? How many people have to get killed or injured before the NHTSA realizes there is an epidemic of rusting brake lines out there? But we seem more concerned with lead paint on toys, and nasty garlic presses (that have injured no one) than an out of control 2 or 3 ton vehicle with a sudden lose of brakes. Where is the justice? Where are the priorities?

WHO I CONTACTED:

1. General Motors (multiple times) - assistance denied - reason was vehicle mileage to high (38,916).

2. NHTSA - filed report

3. ConsumerAffairs.com (twice) - acknowledgement of my letter only.

4. WBRE-TV - acknowledgement of my letter only.

5. Consumer Reports - (twice) received acknowledgement of my letter and it will be forwarded to the appropriate department.

6. Better Business Bureau - said the mileage on my 5 year old vehicle was to high (38,916) for mediation or assistance.

7. LawyerandSettlements.com - (twice) acknowledged my letter and advised me "to seek council"

8. Pa. State Attorney General - responded and they said in part "cannot proceed with legal action on your behalf........because the Commonwealth must establish a pattern or practice of deceptive or unfair conduct......."

9. Scranton Times - but my letter not published

SUPPORTING DOCUMENTATION - I have all records, invoices, Emails, photos of the failing brake lines plus I have the actual rotted lines and backing plates in my possession.

The silence and response to date has been deafening. I can't believe the silence from the consumer and safety advocate organizations, plus the media, around this critical safety issue. It's no longer a matter of recovering any of my costs (although that would be nice as I am retired), it is now a matter of public safety. Someone needs to step up to the plate and acknowledge this is a very serious problem. In the meantime, not to worry, our garlic presses are now less likely to cause bodily injury than my 6000 lb truck if/when it bursts another brake line.

Thank you, respectively,

Joe Palumbo

Clarks Summit (Newton Township)

Comment On This

I am the author of the above article. For pictures and a more complete summary you may go to the link below.

http://sites.google.com/site/gmbadbrakes/

Bottom line, sadly no one cares.

Comment On This

The SAME THING has just happened to my 1999 Buick LeSabre with just over 100k miles. My mechanic is working on it despite the fact that is going to take at least 4-5 hours of labor to fix. He said that most mechanics would not touch such a repair and declare the car totaled.