1999 Chevrolet Silverado 2500 Problems

What owners report

Owners of the 1999 Silverado 2500 mostly write about brakes. The single most common theme is corroded metal brake lines that give way without warning, sometimes during routine braking at ordinary speeds, and many of these trucks were past 80,000 miles when it happened. A smaller but steady group of complaints covers ABS activation at low speed, sticky fuel gauges and sending units, and exhaust manifold bolts that break off.

1. 1
   Brakes

   Rusted-through brake lines and sudden pedal to the floor

   • 21 complaints (26%)
   • median 100,198 mi at 11.7 yrs old (21 state mileage)
   • filed 2005–2015

   Owners describe pressing the brake pedal and having it sink all the way down with little or no braking force, often while slowing for a turn, a stop sign or while backing out of a driveway. Inspection typically found a steel brake line rusted through, sometimes near the rear axle or above the fuel tank, with fluid escaping. Some had the lines replaced; others were told the entire set of hard lines was corroded and needed replacement. Several owners note the body looked clean while the underbody lines were badly rusted. Reported from roughly 58,000 to 185,000 miles, with many clustered between 70,000 and 110,000 miles.

   3 related service bulletins

   What to check: Have the metal brake lines inspected along their full length underneath, especially above the rear axle and fuel tank; a preformed line kit is available for service. Ask for any records of brake line replacement.

   2 excerpts from owner complaints in NHTSA records

   “While driving down the road, I stepped on the brake to stop to turn into my destination when my foot went all the way to the floor. I turned into the parking lot, put the truck into neutral and pulled the emergency brake to stop completely. The truck towed to a local garage when the mechanic stated that the brake line had blown due to rust.”

   NHTSA complaint #10327057, filed 2010-04, 79,173 miles

   “On friday sept. 15, I was driving my 1999 Chevrolet silverado when I experienced brake line rupture from two different locations. I was merely attempting to slow down for a curve and I did 'dynamite' the brakes. I applied normal pressure and suddenly, the pedal began to travel towards the floor and I could feel the vehicle becoming harder to slow. Luckily, I was able to stop the vehicle before suffering an accident. …”

   NHTSA complaint #10355771, filed 2010-09, 108,000 miles
2. 2
   Brakes

   ABS engages at low speed and braking feels weak

   • 13 complaints (16%)
   • median 94,000 mi at 7.8 yrs old (9 state mileage, few)
   • filed 2001–2018

   Complaints describe the ABS kicking in during gentle stops on dry pavement, a grinding or chattering pedal, and the truck rolling further than expected. Some owners say the ABS or brake warning light stayed on, and a few pulled the ABS fuse to get normal braking back. Several mention the wheel speed sensors were rusted, and some owners say the repair was not covered and they paid for it themselves. Mostly reported between about 29,000 and 150,000 miles, on trucks of all ages in the sample.

   What to check: Test the brakes at low speed on a dry surface and watch for ABS or brake warning lights. Ask whether the wheel speed sensors and ABS module have been serviced.

   2 excerpts from owner complaints in NHTSA records

   “My vehicle has the recall issue described in the recall described in NHTSA campaign #: 05v379000 but because I live in colorado, they will not honor the recall. My vehicle antilock brakes malfunction at low speeds intermittently and the vehicle takes a longer distance to completely stop as described in the recall.”

   NHTSA complaint #10210225, filed 2007-11, 123,850 miles

   “Brakes on my 1999 suburban under low speed the anti lock brake system engages and I can not stop in normal braking conditions this is on dry pavement with good tires and the mechanic said that the sensors are rusty and there is a recall I called GM and they are saying mine is not included I had this brake system inspected by a GM mechanic and thy don't understand why mine is on not on list its the same parts as in the recall.”

   NHTSA complaint #10281342, filed 2009-08, 104,000 miles
3. 3
   Fuel system

   Fuel gauge reads wrong and fuel smell or leaks

   • 6 complaints (7%)
   • median 76,476 mi at 11.2 yrs old (4 state mileage, few)
   • filed 2000–2017

   Owners report the fuel gauge reading empty right after a fill or moving erratically, and in some cases a fuel smell with drips under the tank. Complaints describe a corroded fuel line leaking, a plugged tank vent that let the tank collapse and distort the sending unit, and fuel pumps that quit or began to sound different before failing. Repairs ranged from a sending unit or pump replacement to a new fuel tank. Reported from about 52,000 to 100,000 miles, with some at much higher mileage.

   1 related service bulletin

   What to check: Fill the tank and watch whether the gauge reads full and stays steady; check the fuel lines and tank area underneath for rust, dampness or a fuel smell.

   2 excerpts from owner complaints in NHTSA records

   “The fuel gauge malfunctions after filling tank - it reads empty immediately and intermittently thereafter at any fuel level. It makes it difficult for traveling any long distance as you are not quite sure how much fuel is available or if it will shut down on me during a difficult situation. We have contacted GM and they want to charge me to check it and this has been reported as a problem for multiple models to GM.”

   NHTSA complaint #10618019, filed 2014-07, 98,000 miles

   “Vehicle had been running poorly for about 2 weeks maybe more. Fuel pump also was sounding funny. Instead of the normal quick whirring for a few seconds the pump sounded like it was laboring and had a slower, deeper pitch. I thought maybe it was time for tune up but my records showed otherwise. ( I keep pretty extensive vehicle notes on all work/maintenance performed.) on the morning the actual problem finally was discovered I had started my truck after a little more cranking effort than usual. …”

   NHTSA complaint #10557238, filed 2013-12, 298,905 miles
4. 4
   Tires

   Tire blowouts and tread separation

   • 8 complaints (10%)
   • median 37,716 mi at 6.8 yrs old (2 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2000–2006

   Owners describe severe vibration followed by a rear tire failing, tread separating, or the tire losing its sidewall, in some cases damaging the wheel well, exhaust and body panels. A few complaints involve tires that hydroplaned or wore unevenly on the center treads. Most of these are tire-brand issues rather than truck faults, and inspection or replacement was handled through the tire maker or dealer. Reported from about 29,000 to 52,000 miles, generally on the original or early replacement tires.

   What to check: Check DOT date codes on all tires and look for uneven wear or bulging sidewalls; replace any tire showing cracks or separation regardless of tread depth.

   2 excerpts from owner complaints in NHTSA records

   “Submission regarding automobile accident caused by bf goodrich tires (land terrain lt 245/75r 16 load range e DOT n911) seeking reimbursement for repairs. While driving the consumer noticed a severe vibration. As the consumer pulled over to inspect the vehicle the passenger side rear tire blewout. The blowout damaged the right rear quarter panel, muffler, muffler support and tail pipe. It appear to the consumer that the tire tread separated and caused the tire to blowout.”

   NHTSA complaint #10170139, filed 2006-09, 31,022 miles

   “While driving, the right rear kelly trail mark tire lt235/85r16e experienced a blowout causing vehicle to swerve uncontrollably and into another vehicle, the impact caused both vehicles to leave the roadway and a fire to ensue, there was one fatality and 4 injuries. (attorney for client)”

   NHTSA complaint #560739, filed 2001-04
5. 5
   Engine

   Broken exhaust manifold bolts and exhaust tick

   • 5 complaints (6%)
   • median 147,250 mi at 13.3 yrs old (4 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2008–2016

   Complaints describe a ticking or exhaust leak noise traced to broken or missing exhaust manifold bolts, often found while changing spark plugs or wires. Owners say the repair is labor intensive, and one complaint notes hot exhaust escaping near wiring. Some owners said they believed the problem was widespread on these engines. Reported from roughly 85,000 to 193,000 miles in the sample.

   What to check: Listen for a ticking exhaust note at cold start, especially near the manifolds, and have a mechanic check the manifold bolts for breakage before purchase.

   2 excerpts from owner complaints in NHTSA records

   “Broken or missing exhaust manifold bolts causing exhaust leaks. Potential for carbon monoxide leaks into the driving compartment. Upon researching on the internet this seems to be a very common and expensive problem. With GM engines from 1999 to around 2007. Just found this problem on my 1999 silverado on 5/20/16. I have owned this truck since day one and have an excellent service record at a well know dealership. Vehicle was stationary when the problem was diagnosed.”

   NHTSA complaint #10870216, filed 2016-05, 120,000 miles

   “Several of my exhaust manifold bolt heads broke off even though they have never been removed causing hot exhaust to leak out igniting some electrical wiring. My mechanic told me this is a very common problem with GM v8's.”

   NHTSA complaint #10545353, filed 2013-09, 190,000 miles

Buying note. Have any 1999 Silverado 2500 inspected underneath for brake line and fuel line corrosion before buying, since that is the issue owners report most often and it can appear on trucks that look clean on top. Budget for brake line work if records do not show the lines were replaced.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.