For those you implying that the corrosion and brake failure is a fault of poor vehicle maintenance, my husband is a mechanic and I can tell you in no uncertain terms that the maintenance on our truck far exceeds that of most normal owners. Yes, brake fluid has been changed, as well as transmission fluid, amongst other things. He was doing his inspection (part of which was the oil change that was needed) to make sure the truck was ready for my show season when he saw this. I don't know much about cars, but I crawled underneath the truck and just wanted to cry. The entire underside is a rust bucket, which my husband said pretty much started from the day we bought it. They put a rubberized kind of coating on things and almost from day 1, he said it was peeling off. And yes, we live in the salt belt, but this is a garage-kept tow vehicle - I do not tow in the winter. Not to say that it's never seen salt, but not like an everyday driver or plow truck would. Like I said, we have unrestored 40 year old muscle cars at home that have better brake lines/underbodies than our 10 year old truck. So you can try and place the blame on the owner, but I know we have done everything right in taking care of this truck, and it didn't make any difference. And really, does anyone really think it's acceptable for brake lines to be failing in vehicles 10 years old and younger?
And as far as the brake lines rusting from the inside out, I can't comment on that. Based on the condition of our truck, I would assume ours is rusting from the outside in.
An engineer from the NHTSA is coming out to take a look at our truck. Chevrolet had us take our truck to the local dealership for inspection - basically we have a piece of paper now that says the brake system has no leaks, so I guess they consider it safe. Not in our book.
For those of you looking, the brake lines in question are on the driver's side, going into the ABS unit. They are a little hard to see around the frame, which is probably why they are going unnoticed until they are severely corroded. The rest of the brake lines on our truck look good.
I really didn't start this thread to get into a little p*ssing contest about who does vehicle maintenance and who doesn't. Not everyone is married to a mechanic, and not everyone who takes their truck in for service uses a qualified and honest mechanic, so you can try and do everything right and still get burned. I posted it to protect people, maybe prevent someone from being seriously hurt or killed.