This Preliminary Information communication advises the technician that the Hydro-Boost is not serviceable and will need to be replaced if the brake pedal moves or applies on its own at a full turn.
full bulletin at NHTSA ↗2005 Chevrolet Silverado brakes problems
severe 270 complaints filed with NHTSA · avg repair $450 · see brakes across all vehicles →
Failure mileage
Complaints
270
Recalls
0
Avg fix
$450
13crashes
1fire
3injuries
When does it fail?
Of the 270 brakes complaints filed for the 2005 Chevrolet Silverado, here's the actual mileage breakdown — failures cluster heaviest at 25,000-50,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Owners have filed 270 brakes complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
Among the 20 model years of Chevrolet Silverado in our records for brakes problems, this one ranks #3 by owner-complaint volume.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering brakes on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
This informational bulletin provides technicians with a brake lathe calibration procedure.
full bulletin at NHTSA ↗CHEVROLET/GMC/CADILLAC: ANYTIME HYDRAULIC BRAKE PIPES ASSEMBLY NEED REPLACING, PRE-FORMED AND PRE-FLARED BRAKE PIPES ARE AVAILABLE, EXCEPT REAR AXLE CROSSOVER PIPE. MODEL 1999-2007 SILVERADO, SIERRA, 2000-2006 ESCALADE MODELS, AVALANCHE, SUBURBAN, TAHOE, YUKON MODELS. UPDATED 7/18/14. UPDATED 12/9/14.
full bulletin at NHTSA ↗This Preliminary Information communication advises the technician that the Hydro-Boost is not serviceable and will need to be replaced if the brake pedal moves or applies on its own at a full turn.
full bulletin at NHTSA ↗ABS LIGHT ON, DTC'S C0265, C0201, U1041 SET AND/OR LOSS OF COMMUNICATION WITH BRAKE MODULE. (REGROUND EBCM GROUND).
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Brake line corrosion dominates complaints: steel lines rust through, split, or burst between 20,000 and 147,000 miles, often within 6–9 years of ownership. Failures occur in warm climates (North Carolina, Maryland) and cold ones (Michigan, Wisconsin), even on lightly driven trucks. Owners describe lines as brittle, heavily corroded, and impossible to visually inspect without removal. When a line fails, the pedal goes to the floor—no braking. Many drive unaware because warning lights don't always illuminate until significant fluid loss has occurred.
Several owners report the brake pedal going to the floor unexpectedly at highway speed (35–65 mph), creating near-miss collisions or rear-end impacts. One owner lost brakes while towing a 7,000-pound trailer. Another had three separate failures over two years at low speeds—once while backing up a hill with a trailer, once at a stop sign, once descending a mountain. A third complaint involved brakes locking up involuntarily when turning the steering wheel (TSB 1686251 acknowledged), creating sudden loss of control.
Secondary failures are common: rotors warp and develop grooves within 500 miles of resurfacing; bleeder screws freeze from rust; rear rotors fail at 35,000 miles. One rotor casting exploded during a low-speed backing maneuver. Owners cite GM's use of uncoated steel when stainless or poly-coated lines are available, and note older vehicles—1941 and 1989 Chevys, 2000 Fords—have original brake lines in better shape. Repair bills range from $600 to $3,668, with dealers wanting $1,200–$1,800 to replace with the same failing material.
Same Chevrolet Silverado brakes reports on nearby years: 2006 · 2007 · 2008
Failure modes owners describe
Brake line corrosion and rupture
Steel brake lines corrode and rupture, causing partial or complete loss of braking pressure. Lines located under the vehicle frame and along the driver-side frame rail are particularly susceptible. Owners report rust, brittleness, and stress failures at fittings and weak sections. Multiple lines often fail sequentially or nearly simultaneously.
When: 6 to 9 years of ownership; 20,000 to 147,000 miles. Failures occur regardless of climate zone (Midwest salt-belt states, Maryland, Connecticut, Virginia, North Carolina, Washington reported). Some occur in light-use trucks with under 45,000 miles.
Symptoms owners cite: Brake pedal goes to floor with no braking force or reduced braking; Brake fluid leaks observed under driver-side door or rear axle area; Fluid may drip from plastic line brackets or frame connections; No warning lights in many cases despite fluid loss; Brake lines appear heavily rusted, brittle, flaking when inspected; Bleeder screws also rusted and frozen on calipers and wheel cylinders
Repairs/costs cited: Complete brake line replacement required; some owners report $600–$3,668 in dealer costs. Owners replacing with copper-nickel or stainless steel lines; some dealers now using poly-coated lines on replacement units. Master cylinder, calipers, wheel cylinders, and rotors also often require replacement due to corrosion. One owner: $680 replacement with copper-nickel at NAPA versus $1,200 with original material at Chevy dealer; another: $1,800 at Chevy dealer including calipers.
Recalls/TSBs owners mention: GM refused coverage citing normal maintenance; some dealers acknowledged it is a common problem. One owner noted TSB document ID 1686251 for steering-wheel-activated brake locking issue. No manufacturer recall issued for brake line corrosion on 2005 models, though investigation file EA11001 exists for earlier years (1999–2003). One dealer mentioned that new lines now poly-coated to prevent rust.
Unwanted ABS activation at low speed
ABS activates inappropriately during low-speed braking or in dry conditions, causing the brakes to fully release and extend stopping distance. Pedal may go to floor momentarily. Occurs most often while turning or slowing to a stop. Differs from normal ABS which engages on slippery surfaces. Related to corrosion of ABS rotor and sensors.
When: Reported at low mileage (20,000–32,500 miles) and higher (49,600–80,000 miles). Issue noted as persistent across 1999–2006 model years; one owner mentions earlier recall for 1999–2002 trucks that did not resolve the problem.
Symptoms owners cite: ABS engages when not needed (dry pavement, slow speeds); Brake pedal goes to floor during low-speed stop or turn; Increased stopping distance; truck surges forward; ABS release lasts 2+ seconds before re-engaging; delayed brake re-application; Condition more likely when turning while braking; No warning indicator in some cases
Repairs/costs cited: One owner mentioned a temporary sensor installation by dealer. Root cause cited as corroded ABS rotor and sensors. No repair costs detailed in narratives.
Recalls/TSBs owners mention: NHTSA Campaign ID 05V379000 issued a recall for 1999–2002 Chevy trucks (salt-belt states only) addressing ABS activation causing increased stopping distance. However, owners report the same issue in 2005–2006 models, indicating the recall did not extend to later years despite the continued design problem. One dealer stated the issue is widespread but remains unresolved in newer models.
Brake rotor warping and uneven wear
Front brake rotors warp prematurely, causing vibration and pulsation during braking. Grooves reappear within 500 miles of resurfacing. Rear rotors rust and deteriorate rapidly, with failure reported as early as 35,000 miles. One case involved rotor casting failure/explosion.
When: Front rotor issues start at 10,000–12,000 miles. Rear rotor failure at 35,000 miles. Rotor casting failure occurred during backing maneuver (low-speed impact).
Symptoms owners cite: Vibration and pulsation when brakes applied; Front end shakes during braking; Grooves reappear rapidly after resurfacing; Rear rotors severely rusted and deteriorating; In one case: audible 'pop,' right rear wheel locks, rotor casting exploded with pieces jamming drum
Repairs/costs cited: Rotors resurfaced (cut) or replaced multiple times; pads replaced or shaved. One rotor casting failure repair was initially billed to customer despite warranty coverage; another case required full rotor and caliper replacement. Repair costs not detailed for routine rotor work.
Recalls/TSBs owners mention: Dealership initially denied warranty coverage for rotor casting failure, claiming customer contribution. GM Customer Assistance rejected claim. After escalation, dealer agreed to cover under original warranty. No manufacturer statement on design or material defect.
Brake system warning light failures
Brake warning lights fail to illuminate despite active brake system failures (fluid leaks, line ruptures, low pressure). Owners drive unaware of system degradation. In one case, a warning light came on only after significant fluid loss had already occurred.
When: Occurs concurrent with brake line failures and fluid loss; timeline same as line corrosion (6–9 years).
Symptoms owners cite: No warning light despite brake fluid leaking and reservoir level dropping; Pedal softness or floor condition without indicator; Warning light comes on only after extensive fluid loss
Brake-pedal-activated steering-wheel anomaly (rare)
One complaint reported brakes locking up automatically when steering wheel is turned, without foot pedal pressure. Vehicle jerks to one side, creating sudden loss of steering control and unintended braking.
When: Occurred during freeway merge maneuver.
Symptoms owners cite: Brakes apply or lock when steering wheel is turned; No foot pedal input; brakes engage involuntarily; Vehicle jerks to one side during turn; Loss of steering control
Repairs/costs cited: Dealership repaired vehicle and damage from accident at no charge.
Recalls/TSBs owners mention: TSB document ID 1686251 exists addressing this problem. Service representative confirmed Chevrolet is aware but stated vehicle remained unsafe to drive. No recalls or field service bulletins issued to general customer base.
Synthesized from 270 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 3 most recent
The problem addressed in your NHTSA action number: pe05020 for earlier model years of the same truck are occurring in my 2005 truck. This has LED to near rear-end collisions. The brakes go into an "anti-lock" condition at slow speeds while braking, no matter what the weather or road conditions are. You should extend the model years covered in your earlier recall to include all thru 2005 models…
Tl* the contact owns a 2005 Chevrolet silverado 1500. At low speeds the ABS will activate without warrant. This condition causes the vehicle to lurch forward before making a complete stop. The dealer was contacted and they repaired the left side at the owners expense . One month later the right side needed to be repaired at an expense of $848.00. No repairs were made. The failure mileage was…
Pedal goes on down when pressed -- seems like ABS isn't working properly
Had brakes trouble with your 2005 Chevrolet Silverado?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the brakes problem on the 2005 Chevrolet Silverado?
It's a meaningful issue. 270 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $450.
At what mileage does the brakes typically fail?
Across the 253 complaints that reported odometer mileage, most brakes failures cluster between 41,096 and 105,452 miles, with the median around 70,000. A quarter of owners report trouble before 41,096; a quarter make it past 105,452. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $450 for brakes repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to brakes?
No active recalls currently cover brakes issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2005/Chevrolet/Silverado.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.