2002 Chevrolet Camaro

DT*: THE CONTACT STATED THE VEHICLE LOST POWER MULTIPLE TIMES. THE FIRST TIME THE ENGINE COIL BURNED OUT AND WAS REPLACED BY THE DEALERSHIP. THE SECOND TIME THE CATALYTIC CONVERTER WAS PLUGGED AND ENGINE BOLTS HAD BROKEN. THE DEALERSHIP REPLACED THE CATALYTIC CONVERTER AND THE BOLTS. DURING THE THIRD OCCURRENCE THE FOOT THROTTLE BODY SENSOR FAILED AND THE DASH LIGHTS INTERMITTENTLY ILLUMINATED. THE THROTTLE BODY SENSOR WAS REPLACED BY THE DEALERSHIP. DURING ALL THE OCCURRENCES THE VEHICLE LOST POWER WITHOUT WARNING.

IN AUGUST 2002, I PRODUCED BRAKES IN 542 DEPT. AT DELPHI CHASSIS SYSTEMS, DAYTON, OHIO. THE DEPARTMENT WAS SCHEDULED TO CEASE WORK 2 MONTHS AFTER THE END OF GM F-CAR PRODUCTION I WAS PLACED IN INSPECTION BEHIND BRAKE ASSEMBLY. I INSPECTED ALL BRAKES PRODUCED AS SERVICE PARTS. BEFORE I ARRIVED, THERE WERE PROBLEMS WITH POROSITY IN THE BRAKE CASTINGS. INSTEAD OF REQUIRING THE CASTINGS PRODUCER TO BRING IN AN X-RAY MACHINE, GENERAL FOREMAN SAM HANAKERI, ON ORDERS FROM VP GUY HACHEY, INSTALLED AN AIR GUN DRIVER AND WATER TANK TO CHECK PARTS AS THEY RAN. THE AIR GUN WOULD SHOOT A SPECIAL SCREW CONNECTED TO A COMPRESSED AIR CONNECTION, AND THE PART WAS DUNKED WHILE THE COMPRESSED AIR WAS ATTACHED TO THE BRAKE CASTING. THE PROBLEM: THE COMPRESSED AIR ATTACHMENT CROSS THREADED ABOUT 5% OF THE CONNECTION HOLES IN THE CASTING. SINCE THESE CONNECTIONS HAVE TO WITHSTAND HYDRAULIC PRESSURE WHEN THE BRAKES ARE IN USE, CROSS THREADING CAUSES LEAKS AND POTENTIAL BRAKE FAILURE. A GM ASSEMBLY PLANT HAD ISSUED A PRR FOR THE CROSS THREADING, BUT ONLY FOR ONE SIDE OF THE BRAKES DELPHI MANAGEMENT ONLY WANTED TO INSPECT THE THREADS ON THE BRAKES MENTIONED IN THE GM PRR, NOT MIRROR IMAGES. THEY KNEW THAT THE INSPECTION PROCESS DAMAGED BOTH SIDES, BUT WANTED TO IGNORE THE PROBLEMS ON THE NON PRR SIDE. SAM HANAKERI, GF, ORDERED ME TO INSPECT ONLY THE PRR SIDES. HE STATED THAT THE INSPECTION PROCESS CAME FROM GUY HACHEY, AND COULD NOT BE CHANGED OR IMPROVED. I INSPECTED THESE PARTS 60 DAYS. SAM HANAKERI OBJECTED TO THE SCRAP RESULTING FROM MY FINDING BAD THREADS, STATING THAT PREVIOUS INSPECTORS HAD FOUND LESS. I TOLD HIM THAT I SIGNED THE FORMS, AND AS LONG AS MY NAME WAS ON THE FORMS, THEY WOULD REFLECT WHAT I SAW. THESE SERVICE PARTS ARE STILL ON SHELVES. THE ASSEMBLY PARTS HAVE BEEN IN USE SINCE 2002. THE INSPECTION FORMS ARE STILL IN EXISTENCE, MAINTAINED BY BILL ENGLUND AT DELPHI NEED MORE BRAKE PLANT.*JB

CAMARO BOUGHT NOVEMBER 2002, BRAKES AND TIRES REPLACED SIX MONTHS LATER. ENGINE HAD SOUNDED LIKE A DIESEL WITHIN THAT SAME SIX MONTHS TIME. WITHIN THREE YEARS REAR END PRODUCING AN EVER INCREASING HOWL. HAD CONTACTED DEALER TWO TIMES WITHIN FIRST YEAR ABOUT HIGH OIL CONSUMPTION. WAS TOLD IT WAS NORMAL FOR A QUART TO BE LOST WITHIN 3000 MILES. I HAVE TO DRIVE THIS CAR TO WORK AND I REALLY DON'T KNOW WHEN ONE OF MY REAR AXLES IS GOING TO FALL OFF. I CANNOT AFFORD A NEW REAR END AND MY WARRANTY EXPIRED BY MILEAGE. I DON'T KNOW IF THIS IS GOING TO DO MUCH GOOD BUT IT FEEL GOOD TO BE ABLE TO WRITE ABOUT WHAT A 33,000 BLACK CAMARO PIECE OF CRAP CAN DO TO A MAN WHO HAS ALWAYS BEEN LOYAL AS POSSIBLE TO CHEVY AND HAD A DREAM TO OWN SUCH A CAR ONLY TO FIND OUT HE WOULD HAVE BEEN BETTER OFF WITH A HYUNDAI. I WILL TELL YOU ONE THING AND MAYBE THIS WILL TELL YOU WHAT I REALLY THINK OF CHEVY AND THEIR CARS. I WOULDN'T WISH THIS PURCHASE ON MY WORST ENEMY. BIGGEST MISTAKE OF MY LIFE WAS BELIEVING IN CHEVY. *JB

INTERMITTENTLY THE BRAKE PEDAL SHUTTERED/SHIMMIED AND PULSATED WHEN DEPRESSED. THIS WAS DUE TO A FAILURE IN THE BRAKE ROTORS. THE FAILURE HAS OCCURRED AT 7000, 12419 ,18830,26754, AND 27310 MILES, THE ROTORS WERE RESURFACED/REPLACED/TURNED. AND BRAKE SHIMS HAD BEEN ADDED. IN ADDITION THE BRAKE PAD AND SHOES WERE REPLACED 4 TIMES.*AK THE CONSUMER WAS ADVISED TO PURCHASE A HIGHER QUALITY OFF THE MARKET ROTOR AT $500.00 PER ROTOR. *TC