Lost brakes, almost "T - Boned"

chromebumpers

solid fixture here in the forum
Staff member
2006 Silverado HD2500, LT, Diesel, Crew cab, 49K miles -

On Sat. I approached a stop sign on a four point rural hilltop. I just barely got started when out of nowhere came speed racer in a Mazda. I stood on the brakes and watched as this guy was headed towards my door. He did manage to zig-zaged at the last possible nano second, and past me without hesitation. When I got to the next stop sign I didn't have brakes. I used the trans-brake and careful planning to get home on country back roads - about eight miles. I filled the master cylinder with bf and cleaned all around with brake cleaner and let dry. Trying the brakes again and lost the fluid but I cannot see where it's leaking. Today I put the truck on the lift and using a Phoenix reverse pump on a back wheels I finally found a pinhole in one of the brake lines. There is a slow leak where the master attaches to the booster and dripped on a bundled set of brake lines and caused corrosion eating at least 2 brake lines directly under the master cyl. I think the line was weakened to the point where jamming the brakes was the end.
I wonder if GM has seen this on other trucks? It's out of warranty, should I try to report this? Perhaps it's a beginning to a recall? Is there some parts supplier besides a dealer and NAPA that would carry pre-formed brake lines? These lines are tucked in and very tight between the rail and everything else - I wouldn't even begin to fabricate my own line, it would drive me insane to follow a dozen or more bends! I'll edit this thread with a picture in a bit.
 
pictures would be great!
brake fluid normally doesn,t eat at steel brake lines so Im rather confused here! sounds like something other than clean new brake fluid was used in the system
 
There isn't any corrosion on any other part of these brake lines (splitter here)


silver06brake004.jpg


except here - staring here

No peeling paint anywhere on the chassie except under those lines. The master is right above this.

silver06brake005.jpg




silver06brake003.jpg


This view is behind the tire in the wheel well.

silver06brake002.jpg



I called the dealer and they said the lines are not pre-made. Are these lines coated copper? remember corrosion killed the oem line. what degree flare is on brake lines? looks like 1/4 inch.
 
grumpyvette said:
pictures would be great!
brake fluid normally doesn,t eat at steel brake lines so Im rather confused here! sounds like something other than clean new brake fluid was used in the system

Well something is! NAPA only sells copper and coated copper should I be buying steel? These corroded lines are directly under the master cyl. but I cannot see any active leaking (cleaned everything with brake cleaner) painted frame is peeling/bubbling paint off under these lines).
 
theres no question brake fluid eats paint,and absorbs moisture from the air, so that would cause the much lower resistance to moisture on metal surfaces and rust easily forming but that leak must have been present for months or even years to cause that much rust
 

I'm not sure they even have what you need, but maybe if you called them.

http://www.classictube.com/GMC_truck_br ... lines.html

Classic Tube manufactures precision prebent tubing in stainless steel, O.E, steel or aluminum-complete with fittings - for your car, truck or fleet vehicle. Our state-of-the-art computer-driven CNC tube benders can match bends from blueprints or original lines. We have many lines in stock or we can make custom lines to your specifications.

 
grumpyvette said:
is the battery located near that location, it looks like battery acid spill damage, or someone spilled pool chlorine on those lines

No, there are 2 batteries in this truck one is left front the other is right rear above ac/heater box - Come to think about it, why do I need 2 batteries anyway? I don't have a plow package, no big stereo or dvd player. Is it that much draw to start a diesel?
 
Indycars said:

I'm not sure they even have what you need, but maybe if you called them.

http://www.classictube.com/GMC_truck_br ... lines.html

Classic Tube manufactures precision prebent tubing in stainless steel, O.E, steel or aluminum-complete with fittings - for your car, truck or fleet vehicle. Our state-of-the-art computer-driven CNC tube benders can match bends from blueprints or original lines. We have many lines in stock or we can make custom lines to your specifications.


Thanks Indycars. I just got off the phone from the brake line guys. They don't have anything for my truck - go figure, they only made 10s of thousands of this truck!
Anyway, they need me to send them all the lines so they can copy them. $329 for a set. I cannot be without my truck for two weeks! I have to make something in the meanwhile. I need a 45 degree double inverted flare and i don't think I can do that on my regular flare tool, guess I'll have to find one (at least I have a good hand held bender). Ps. I don't under stand this - the guy said this happens to the brake lines and is common. I pointed out that except for a 10 inches area, the remaining line is rust/corrosion free - he says other spots will come. I think something leaked on these line in that one spot.
Can I call you something besides 'Indycars?"
 
chromebumpers said:
Thanks Indycars. I just got off the phone from the brake line guys. They don't have anything for my truck - go figure, they only made 10s of thousands of this truck!
Anyway, they need me to send them all the lines so they can copy them. $329 for a set. I cannot be without my truck for two weeks! I have to make something in the meanwhile. I need a 45 degree double inverted flare and i don't think I can do that on my regular flare tool, guess I'll have to find one (at least I have a good hand held bender). Ps. I don't under stand this - the guy said this happens to the brake lines and is common. I pointed out that except for a 10 inches area, the remaining line is rust/corrosion free - he says other spots will come. I think something leaked on these line in that one spot.
Can I call you something besides 'Indycars?"

Sorry they didn't have anything, but it was worth a try I suppose.

Since your are in Pennsylvania the road salt must be pretty heavy, but that
don't explain why it's just in the one area of the truck.

I've also been know to answer to Rick.

 
chromebumpers said:
grumpyvette said:
is the battery located near that location, it looks like battery acid spill damage, or someone spilled pool chlorine on those lines

No, there are 2 batteries in this truck one is left front the other is right rear above ac/heater box - Come to think about it, why do I need 2 batteries anyway? I don't have a plow package, no big stereo or dvd player. Is it that much draw to start a diesel?
you need 2 batt for a diesel truck because the glowplug draw some good current and since the engine is higher compression the starter is bigger and also draw more current. keep the 2 battery, its needed especially for cold starting/long cranking. The electronic injection pump on some model (like my 94 chevy)also draw about 25 amps.
 
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