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GMC Yukon XLModel years 2000–2006

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BrakesModel years 1999–2002ManufacturerGovernment

Parking brake linings worn out prematurely, parking brake does not hold (PBR single-shoe drum-in-hat)

ODI's EA04-011 subject vehicles are MY 1999-2003 Silverado/Sierra 1500 pickups with manual transmissions. The closing report states that premature wear-out complaints came from all MY 1999-2002 C/K 1500 trucks regardless of transmission type, that data were collected on automatic-transmission GM C/K pickups and sport-utility vehicles based on the same platform, and that bulletin 02-05-26-002A added Suburban and Yukon XL. Petition DP05-009 names "2000-2003 GMC Yukon" and GM's notice names "2000-2005 GMC Yukon Models" (1500 series in both); ODI's investigation itself did not take the sport-utility vehicles as its subject. Recall 05V-161 covers manual-transmission pickups only. The original bulletin 02-05-26-002 (as listed in TechLink, December 2002) names the 2000-03 Chevrolet Tahoe and GMC Yukon 1500 series. GM's bulletins and the petition also name model year 2003, while ODI limits the defect to model years 1999-2002.

FaultCrate・Parking brake linings worn out prematurely, parking brake does not hold (PBR single-shoe drum-in-hat)

ODI is aware of over 600 complaints of premature parking brake wear-out in all MY 1999-2002 C/K 1500 trucks, regardless of transmission type; most involved vehicles with 20,000-60,000 miles (= 32,187–96,561 km), or 15-41 months in service.

Most complaints (over 90%) concerned a worn out or inoperative parking brake system, usually discovered during a service visit or mandatory state safety inspection.

Very few of the interviewed owners had noticed noises or any other sign that the park brake had been engaged.

The parking brake friction linings may wear out prematurely, leaving the parking brake ineffective.

The petitioner states that some customers may notice a scraping noise from the rear of the vehicle and that in most instances the parking brake was completely worn out by 25,000 miles (= 40,234 km).

The parking brake is a drum-in-hat design with a single brake shoe bearing two friction linings (a "Banksia"-style brake). The shoe is expanded by a cable-actuated piston and held against the backing plate by a spring-loaded hold-down clip.

The linings wear out prematurely after one of them remains in contact with the drum surface while driving: the shoe pivots about the piston assembly so that the end of one lining rests against the drum.

Drum motion during driving self-energizes the brake and keeps the lining in contact, even when the parking brake has not been applied. GM found that the original-design hold down clip contributed by preventing the shoe from retracting the lining away from the drum.

GM attributed the accelerated wear to foreign material intrusion and a failure of the brake shoe to properly self-center within its brake drum.

The petitioner says GM told it of a technical service bulletin referencing an improper clip that, under normal driving conditions, allows the parking brake shoes to remain in contact with the rotor.

What to do

  1. On complaint vehicles examined in the field, wear occurred earlier and to a greater extent on the driver's side parking brake unit and was largely localized at the tip of one of the linings.
  2. Bulletin 01-05-26-001 "Park Brake - Low Effort Apply System Description" (Mar 2001) describes a park brake test procedure.
  3. A revised clip designed to exert less force on the shoe went into MY 2003 production and into the service part stream. Installing the newer clip and replacing worn linings has been shown to remedy the defect.
  4. The closing report lists a bulletin of Aug 2004 as 02-05-26-001B "Brakes - Parking Brake Shoe Retainer Clip Availability", announcing a new retainer clip service kit for DIH-equipped vehicles.
  5. In the recall, dealers install a low-force spring clip retainer on vehicles with the PBR parking brake system and a redesigned parking brake cable assembly on vehicles with the TRW parking brake system.
  6. That bulletin releases a rear parking brake retaining spring clip kit for service: two parking brake hold down spring clips and bolts.
  7. The clip can be damaged during rear brake rotor removal; the kit is ordered when the clips need replacing but the parking brake shoes do not.
  8. Kit 88982879 is the parking brake retainer spring clip kit for C/K, M/L and G models.
  9. The correction is to replace the parking brake shoe kit and clean the drum-in-hat rotor.

Part numbers printed in the document

The numbers are as the document prints them. The name and the replacing number are what the pages of GMPartsGiant, a reseller of genuine parts and not GM, state. Aftermarket equivalents are not checked here (the links only search by number). Confirm the fit for the vehicle (VIN) before ordering.

If left

  • ODI's chief concern was that an unattended vehicle with an ineffective parking brake may inadvertently roll, striking persons or property.

Caution

  • The vehicles warn the operator with a chime if driven over 3 mph (= 4.83 km/h) with the parking brake engaged.
  • GM states that the parking brake is intended strictly as a parking assist device to be used with proper transmission settings, that suspension/wheel modifications and off-road driving may accelerate parking brake wear, and that owners should periodically test the parking brake's holding power.
  • The conditions GM described are also present in C/K trucks with automatic transmissions, but the rollaway rate in those vehicles was similar to that of peer vehicles studied by ODI.
  • This Engineering Analysis is closed because GM's recall action will remedy the defect condition in the MY 1999 - 2002 C/K 1500 pickup trucks equipped with manual transmissions.
  • The petitioner reports that several complainants had parking brake failures even after the redesigned clip was installed, leading to replacement of the parking brake shoes and rotors.
  • Remove the rotor with the J 46277 Rotor Removal Tool and J 6125-B Slide Hammer, placing J 46277 between the rotor surfaces in the vent section; do not place it on the back side of the rotor surface, which may damage the rotor surface.
  • The bulletin itself states that the spring clip kits do not address any parking brake concerns and refers to the Parking Brakes sub-section of the Service Manual for diagnosis.
  • ODI denied the petition.
  • ODI's review of complaint data received since the close of EA04-011 revealed no indication that the investigation should be re-opened; ODI reserves the right to reopen it should conditions warrant.

In the records

  • Parking Brake: adjusted 2（says it held for a while: 1, result not stated: 1）
  • Parking Brake: replaced 2（result not stated: 2）
  • ABS Fuse: replaced 1（result not stated: 1）
  • Brake Drum: repaired 1（says it came back: 1）

Applies to

  • ODI collected data on the manual-transmission Silverado/Sierra 1500 pickups (the subject vehicles) and on peer vehicles, including all MY 1999-2004 automatic-transmission GM C/K pickups and sport-utility vehicles based on the same platform.
  • The subject brake system is used in over 4 million MY 1999 - 2004 C/K 1500 vehicles; field data and manufacturing changes indicate that the defect is present only in the MY 1999 - 2002 vehicles.
  • Bulletin 02-05-26-002 "Brakes - Scraping Noises from Rear of Vehicle" (Oct 2002) announced the low-force clip for certain ½ ton GMT800s; 02-05-26-002A (Feb 2003) added Suburban and Yukon XL.
  • From the start of MY 2003 production, GM's C/K 1500 trucks were equipped with the newer lower force hold-down clip.
  • MY 2005 vehicles with this system have two hold-down clips, which further enhance the brake shoe's ability to self-center.
  • ODI received a petition asking it to investigate certain GM full-sized pickup trucks and utilities with "drum-in-hat" (DIH) parking brakes.
  • The petition names 2002-2003 Cadillac Escalade, 1999-2003 Chevrolet Silverado, 2000-2003 Chevrolet Suburban and Tahoe, 2002-2003 Chevrolet Avalanche, 1999-2003 GMC Sierra and 2000-2003 GMC Yukon.
  • According to the petitioner, the complaints reference vehicles with drum-in-hat rotors and seem to be limited to vehicles with a low-effort parking brake system.
  • The bulletin's model list includes 2000-2005 GMC Yukon Models; the bulletin applies only to 1500 series vehicles with four wheel disc brakes.
  • Bulletin 02-05-26-002, scraping noise from the rear of the vehicle, lists 2002-03 Cadillac Escalade, EXT and Chevrolet Avalanche, 1999-2003 Chevrolet Silverado and GMC Sierra 1500 series, and 2000-03 Chevrolet Tahoe and GMC Yukon 1500 series.
See the evidence (3 documents, 39 passages)
DocumentPublisherDate
[1]ODI investigation EA04011: Parking Brake Failure ↗
GovernmentNHTSA ODI
2005-05-10
[2]ODI investigation DP05009: Parking Brake Failure ↗
GovernmentNHTSA ODI
2006-05-31
[3]GM TechLink, December 2002 ↗
ManufacturerGeneral Motors
2002-12-01

  • Applies toODI collected data on the manual-transmission Silverado/Sierra 1500 pickups (the subject vehicles) and on peer vehicles, including all MY 1999-2004 automatic-transmission GM C/K pickups and sport-utility vehicles based on the same platform.

    During the investigation, ODI collected data concerning the manual transmission-equipped Silverado/Sierra 1500 pickups (subject vehicles) and millions of peer vehicles that included ½ ton pickup trucks manufactured by Ford and Dodge, as well as all MY 1999 - 2004 automatic transmission-equipped GM C/K pickups and sport-utility vehicles based on the same platform as that used in the subject vehicles.— [1]

  • Applies toThe subject brake system is used in over 4 million MY 1999 - 2004 C/K 1500 vehicles; field data and manufacturing changes indicate that the defect is present only in the MY 1999 - 2002 vehicles.

    The subject brake system is used in over 4 million MY 1999 - 2004 C/K 1500 vehicles. Field data and manufacturing changes indicate that the defect is present only in the MY 1999 - 2002 vehicles.— [1]

  • Applies toBulletin 02-05-26-002 "Brakes - Scraping Noises from Rear of Vehicle" (Oct 2002) announced the low-force clip for certain ½ ton GMT800s; 02-05-26-002A (Feb 2003) added Suburban and Yukon XL.

    Oct-2002 02-05-26-002 "Brakes- Scraping Noises from Rear of Vehicle" Announced the availability of the low-force clip in certain ½ ton GMT800s Feb-2003 02-05-26-002A "Brakes- Scraping Noises from Rear of Vehicle" Adds Suburban and Yukon XL to earlier models— [1]

  • First signsODI is aware of over 600 complaints of premature parking brake wear-out in all MY 1999-2002 C/K 1500 trucks, regardless of transmission type; most involved vehicles with 20,000-60,000 miles (= 32,187–96,561 km), or 15-41 months in service.

    To date, ODI is aware of over 600 nonduplicative consumer complaints³ reporting premature parking brake wear-out in all MY 1999-2002 C/K 1500 trucks, regardless of transmission type. The majority of complaints involved vehicles that had accumulated 20,000 - 60,000 miles, or 15 - 41 months in service.— [1]

  • First signsMost complaints (over 90%) concerned a worn out or inoperative parking brake system, usually discovered during a service visit or mandatory state safety inspection.

    Most (over 90%) expressed concern over a worn out or inoperative parking brake system, usually discovered during a service visit or mandatory state safety inspection.— [1]

  • First signsVery few of the interviewed owners had noticed noises or any other sign that the park brake had been engaged.

    Very few of the interviewed owners indicated that they had noticed noises or any other sign that the park brake had been engaged.— [1]

  • Why it happensThe parking brake is a drum-in-hat design with a single brake shoe bearing two friction linings (a "Banksia"-style brake). The shoe is expanded by a cable-actuated piston and held against the backing plate by a spring-loaded hold-down clip.

    This parking brake system is distinguished from other DIH designs in that it contains a single brake shoe bearing two friction linings (Item 1 in Figure 1) and is referred to as a "Banksia"-style brake. The brake shoe is expanded by a cable-actuated piston and is confined against the backing plate by a spring- loaded hold-down clip (Item 2 in Figure 1).— [1]

  • Why it happensThe linings wear out prematurely after one of them remains in contact with the drum surface while driving: the shoe pivots about the piston assembly so that the end of one lining rests against the drum.

    The alleged defect has been identified as premature wear-out of the parking brake linings after one of them remains in contact with the brake drum surface while driving. This condition is characterized by the brake shoe pivoting about the piston assembly within the plane of the brake system backing plate so that the end of one of its linings rests against the drum surface.— [1]

  • Why it happensDrum motion during driving self-energizes the brake and keeps the lining in contact, even when the parking brake has not been applied. GM found that the original-design hold down clip contributed by preventing the shoe from retracting the lining away from the drum.

    Relative motion of the drum during driving acts to self-energize the brake so as to maintain the drum/lining contact and may occur even in the absence of a parking brake application². GM analysis found that the original-design hold down clip (Figure 2) contributed to this condition by preventing the shoe from retracting the lining away from the drum surface.— [1]

  • Why it happensGM attributed the accelerated wear to foreign material intrusion and a failure of the brake shoe to properly self-center within its brake drum.

    GM has attributed this accelerated wear to foreign material intrusion and a failure of the brake shoe to properly self-center within its brake drum.— [1]

  • How to confirmOn complaint vehicles examined in the field, wear occurred earlier and to a greater extent on the driver's side parking brake unit and was largely localized at the tip of one of the linings.

    Examination of complaint vehicles in the field showed that wear occurred earlier and to a greater extent on the driver's side parking brake unit and was largely localized at the tip of one of the linings.— [1]

  • How to confirmBulletin 01-05-26-001 "Park Brake - Low Effort Apply System Description" (Mar 2001) describes a park brake test procedure.

    Mar-2001 01-05-26-001 "Park Brake- Low Effort Apply System Description" Indicates that new parking brake systems require less pedal force and are self- adjusting; Describes a park brake test procedure— [1]

  • RepairA revised clip designed to exert less force on the shoe went into MY 2003 production and into the service part stream. Installing the newer clip and replacing worn linings has been shown to remedy the defect.

    A revised clip (Figure 3) designed to exert less force on the shoe was introduced into MY 2003 vehicle production and was concurrently released into the service part stream. Installation of the newer clip and replacement of worn linings has been shown to remedy the defect.— [1]

  • RepairThe closing report lists a bulletin of Aug 2004 as 02-05-26-001B "Brakes - Parking Brake Shoe Retainer Clip Availability", announcing a new retainer clip service kit for DIH-equipped vehicles.

    Aug-2004 02-05-26-001B "Brakes- Parking Brake Shoe Retainer Clip Availability" Announces availability of new retainer clip service kit for DIH-equipped vehicles— [1]

  • Applies toFrom the start of MY 2003 production, GM's C/K 1500 trucks were equipped with the newer lower force hold-down clip.

    Effective with the start of MY 2003 production, GM's C/K 1500 trucks were equipped with the newer lower force hold-down clip.— [1]

  • Applies toMY 2005 vehicles with this system have two hold-down clips, which further enhance the brake shoe's ability to self-center.

    MY 2005 vehicles containing this system have received two hold-down clips, which further enhance the brake shoe's ability to self-center.— [1]

  • If leftODI's chief concern was that an unattended vehicle with an ineffective parking brake may inadvertently roll, striking persons or property.

    ODI's chief concern in this investigation has been the possibility that an unattended vehicle containing an ineffective parking brake may inadvertently roll, striking persons or property.— [1]

  • CautionThe vehicles warn the operator with a chime if driven over 3 mph (= 4.83 km/h) with the parking brake engaged.

    The subject vehicles will warn their operators with a chime if the vehicle is driven over 3 mph with the parking brake engaged.— [1]

  • CautionGM states that the parking brake is intended strictly as a parking assist device to be used with proper transmission settings, that suspension/wheel modifications and off-road driving may accelerate parking brake wear, and that owners should periodically test the parking brake's holding power.

    GM has stated that the parking brake system in the subject vehicles is intended strictly for use as a parking assist device, to be used in concert with proper transmission settings, that certain use conditions including suspension/wheel modifications and off-road driving may accelerate parking brake wear, and that vehicle owners should periodically test their parking brakes to verify their holding power.— [1]

  • CautionThe conditions GM described are also present in C/K trucks with automatic transmissions, but the rollaway rate in those vehicles was similar to that of peer vehicles studied by ODI.

    Though the conditions described in GM's letter are also present in the C/K trucks with automatic transmissions, the rollaway rate in those vehicles was similar to those observed in peer vehicles studied by ODI in this investigation.— [1]

  • CautionThis Engineering Analysis is closed because GM's recall action will remedy the defect condition in the MY 1999 - 2002 C/K 1500 pickup trucks equipped with manual transmissions.

    This Engineering Analysis is closed because GM's recall action will remedy the defect condition in the MY 1999 - 2002 C/K 1500 pickup trucks equipped with manual transmissions.— [1]

  • RepairIn the recall, dealers install a low-force spring clip retainer on vehicles with the PBR parking brake system and a redesigned parking brake cable assembly on vehicles with the TRW parking brake system.

    Dealers will install a low- force spring clip retainer for vehicles equipped with the PBR parking brake system and install a redesigned parking brake cable assembly on vehicles equipped with the TRW parking brake system.— [1]

  • Applies toODI received a petition asking it to investigate certain GM full-sized pickup trucks and utilities with "drum-in-hat" (DIH) parking brakes.

    ODI has received a petition requesting investigation of certain GM full-sized pickup trucks and utilities equipped with "drum-in-hat" (DIH) parking brakes.— [2]

  • Applies toThe petition names 2002-2003 Cadillac Escalade, 1999-2003 Chevrolet Silverado, 2000-2003 Chevrolet Suburban and Tahoe, 2002-2003 Chevrolet Avalanche, 1999-2003 GMC Sierra and 2000-2003 GMC Yukon.

    At this time I request an investigation into parking brake failures on 2002-2003 Cadillac Escalade, 1999-2003 Chevrolet Silverado, 2000-2003 Chevrolet Suburban and Tahoe, 2002-2003 Chevrolet Avalanche, 1999-2003 GMC Sierra, 2000-2003 GMC Yukon— [2]

  • Applies toAccording to the petitioner, the complaints reference vehicles with drum-in-hat rotors and seem to be limited to vehicles with a low-effort parking brake system.

    Complaints reference vehicles equipped with drum-in-hat rotors and seem to be limited to those vehicles equipped with a low-effort parking brake system.— [2]

  • First signsThe parking brake friction linings may wear out prematurely, leaving the parking brake ineffective.

    The parking brake friction linings may wear out prematurely, rendering the parking brake ineffective.— [2]

  • First signsThe petitioner states that some customers may notice a scraping noise from the rear of the vehicle and that in most instances the parking brake was completely worn out by 25,000 miles (= 40,234 km).

    Some customers may notice a scraping noise coming from the rear of the vehicle. In most instances, the parking brake was completely worn out by 25,000 miles.— [2]

  • Why it happensThe petitioner says GM told it of a technical service bulletin referencing an improper clip that, under normal driving conditions, allows the parking brake shoes to remain in contact with the rotor.

    General Motors has informed us of a technical service bulletin that references an improper clip installed that will, under normal driving conditions, allow the parking brake shoes to remain in contact with the rotor.— [2]

  • CautionThe petitioner reports that several complainants had parking brake failures even after the redesigned clip was installed, leading to replacement of the parking brake shoes and rotors.

    Several complainants reference parking brake failures even after the redesigned clip has been installed, leading to replacement of the parking brake shoes and rotors.— [2]

  • Applies toThe bulletin's model list includes 2000-2005 GMC Yukon Models; the bulletin applies only to 1500 series vehicles with four wheel disc brakes.

    2000-2005 GMC Yukon Models 2002-2005 GMC Envoy Models 2003-2005 GMC Safari, Savana 1998-2004 Oldsmobile Bravada This Bulletin ONLY applies to 1500 series vehicles with four wheel disc brakes.— [2]

  • RepairThat bulletin releases a rear parking brake retaining spring clip kit for service: two parking brake hold down spring clips and bolts.

    A rear parking brake retaining spring clip kit has been released for service. This kit consists of two parking brake hold down spring clips (2) and bolts (3).— [2]

  • RepairThe clip can be damaged during rear brake rotor removal; the kit is ordered when the clips need replacing but the parking brake shoes do not.

    During rear brake rotor removal, it is possible to damage the parking brake shoe retaining spring clip. Order this new kit when replacement of the clips is required but the parking brake shoes do not require replacement.— [2]

  • RepairKit 88982879 is the parking brake retainer spring clip kit for C/K, M/L and G models.

    88982879 Spring Clip, Parking Brake Retainer Kit (C/K, M/L, G Models)— [2]

  • CautionRemove the rotor with the J 46277 Rotor Removal Tool and J 6125-B Slide Hammer, placing J 46277 between the rotor surfaces in the vent section; do not place it on the back side of the rotor surface, which may damage the rotor surface.

    Use J 46277 Rotor Removal Tool with J 6125-B Slide Hammer to remove the rotor from the vehicle. Place J 46277 between the rotor surfaces in the vent section of the rotor. DO NOT place J 46277 on the back side of the rotor surface, it may damage the rotor surface.— [2]

  • CautionThe bulletin itself states that the spring clip kits do not address any parking brake concerns and refers to the Parking Brakes sub-section of the Service Manual for diagnosis.

    The spring clip kits mentioned in this bulletin do not address any parking brake concerns. Refer to the Parking Brakes sub-section of the Service Manual for any diagnostic information.— [2]

  • CautionODI denied the petition.

    THE PETITION IS DENIED— [2]

  • CautionODI's review of complaint data received since the close of EA04-011 revealed no indication that the investigation should be re-opened; ODI reserves the right to reopen it should conditions warrant.

    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.— [2]

  • Applies toBulletin 02-05-26-002, scraping noise from the rear of the vehicle, lists 2002-03 Cadillac Escalade, EXT and Chevrolet Avalanche, 1999-2003 Chevrolet Silverado and GMC Sierra 1500 series, and 2000-03 Chevrolet Tahoe and GMC Yukon 1500 series.

    02-05-26-002; Scraping Noise From Rear of Vehicle (Replace Parking Brake Shoe Kit and Clean Drum in Hat Rotor); 2002-03 Cadillac Escalade, EXT and Chevrolet Avalanche, 1999-2003 Chevrolet Silverado and GMC Sierra 1500 Series, 2000-03 Chevrolet Tahoe and GMC Yukon 1500 Series— [3]

  • RepairThe correction is to replace the parking brake shoe kit and clean the drum-in-hat rotor.

    Scraping Noise From Rear of Vehicle (Replace Parking Brake Shoe Kit and Clean Drum in Hat Rotor)— [3]

Put together by FaultCrate from public records and technical documents. The cause and the repair are for the workshop to decide with the vehicle in front of it. Counts are records, not failure rates.

Records under this issue 35

Owner complaint 35

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