NHTSA owner reports · September 18, 2026 snapshot.
Electrical System complaints
106 reportsClear category filter51,900 miles · Mar 13, 2012
Electrical System
TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT WHEN DRIVING AT VARIOUS SPEEDS, ALL OF THE GAUGES ON THE INSTRUMENT PANEL CLUSTER FAILED. THE VEHICLE WAS TAKEN TO A DEALER AND THEY ADVISED HIM THAT THE CLUSTER NEEDED TO BE REPLACED. THE MANUFACTURER WAS CONTACTED AND THEY OFFERED TO PAY HALF OF THE REPAIR…
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TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT WHEN DRIVING AT VARIOUS SPEEDS, ALL OF THE GAUGES ON THE INSTRUMENT PANEL CLUSTER FAILED. THE VEHICLE WAS TAKEN TO A DEALER AND THEY ADVISED HIM THAT THE CLUSTER NEEDED TO BE REPLACED. THE MANUFACTURER WAS CONTACTED AND THEY OFFERED TO PAY HALF OF THE REPAIR COST. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 51,900.
NHTSA ODI #10451463
155,000 miles · Jan 4, 2012
Electrical System
SPEEDOMETER STOPPED WORKING AND IS STUCK ON 52 MPH. FUEL GAUGE IS STUCK ON FULL, TEMPERATURE GAUGE IS POINTING TO NOWHERE, AND THE TACOMETER IS POINTING AT ZERO. IT SEEMS TO BE A COMMON PROBLEM WITH THIS VEHICLE. *TR
NHTSA ODI #10442330
39,000 miles · Jan 3, 2012
Electrical System
SPEEDOMETER IS NOT WORKING LOOKS LIKE THERE'S BEEN SEVERAL COMPLAINTS ON THE INTERNET ABOUT THIS ISSUE WITH OTHER CHEVROLET CAVALIERS. *TR
NHTSA ODI #10442233
89,000 miles · Nov 29, 2011
Electrical System
THE INSTRUMENT PANEL STOPPED WORKING. I ORDERED 2 USED ONES THEY DID NOT WORK. I HAD THE DEALERSHIP REBUILD IT AND IT STILL DOES NOT WORK. I HAVE SEARCHED ONLINE AND SEVERAL PEOPLE HAVE THE SAME PROBLEM. GM HAS RECALLED THIS ITEM ON SEVERAL MODELS BUT NOT ON THE CAVALIER AS OF YET. I HAVE SPENT HUNDREDS AND STILL HAVE NOT FIXED …
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THE INSTRUMENT PANEL STOPPED WORKING. I ORDERED 2 USED ONES THEY DID NOT WORK. I HAD THE DEALERSHIP REBUILD IT AND IT STILL DOES NOT WORK. I HAVE SEARCHED ONLINE AND SEVERAL PEOPLE HAVE THE SAME PROBLEM. GM HAS RECALLED THIS ITEM ON SEVERAL MODELS BUT NOT ON THE CAVALIER AS OF YET. I HAVE SPENT HUNDREDS AND STILL HAVE NOT FIXED THE PROBLEM. NO SPEEDOMETER, GAS GAUGE. *KB
NHTSA ODI #10437773
60,000 miles · Sep 7, 2011
Electrical SystemFuel System, Gasoline
SPEEDOMETER GOES HAYWIRE SO YOU HAVE NO IDEA HOW FAST YOU ARE GOING. OTHER GAUGES (FUEL, TEMP) ALSO ERRATIC. SEEMS THIS IS A COMMON PROBLEM WITH MANY GM VEHICLES AND IS VERY DANGEROUS! *TR
NHTSA ODI #10424123
63,000 miles · Aug 26, 2011
Electrical SystemFuel System, Gasoline
TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT WHILE DRIVING MPH AND ABOVE, THE SPEEDOMETER AND TEMPERATURE GAUGES WOULD NOT ILLUMINATE. IN ADDITION, THE FUEL GAUGE WAS PROVIDING INACCURATE FUEL LEVEL READINGS. THE VEHICLE WAS NEITHER INSPECTED NOR REPAIRED. THE MANUFACTURER WAS CONTACTED AND THEY OFFERE…
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TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT WHILE DRIVING MPH AND ABOVE, THE SPEEDOMETER AND TEMPERATURE GAUGES WOULD NOT ILLUMINATE. IN ADDITION, THE FUEL GAUGE WAS PROVIDING INACCURATE FUEL LEVEL READINGS. THE VEHICLE WAS NEITHER INSPECTED NOR REPAIRED. THE MANUFACTURER WAS CONTACTED AND THEY OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 63,000.
NHTSA ODI #10421599
Mileage unknown · Jul 27, 2011
Electrical System
ALL GAUGES WORK ERRATICALLY OR NOT AT ALL. LOTS OF OTHER PEOPLE HAVING SIMILAR PROBLEM. READ THERE STORIES HERE: HTTP://WWW.CARCOMPLAINTS.COM/CHEVROLET/CAVALIER/2005/ELECTRICAL/GAUGES_HAVE_GONE_HAYWIRE.SHTML. *TR
NHTSA ODI #10415365
30,000 miles · Jul 5, 2011
Electrical SystemEngine And Engine CoolingFuel System, Gasoline
I AM THE OWNER OF A 2003 CHEVY CAVALIER AND I HAVE 2 COMPLAINTS THAT SHOULD HAVE BEEN RECALLS AS THERE ARE MANY WITH THE SAME 2 PROBLEMS, FIRST EVERY GAUGE IN MY CAR QUIT WORKING NO RPM, NO GAS GUAGE AND NO SPEEDOMETER. SECOND EVER SINCE I BOUGHT MY CAR FOR NO REASON AT ALL IT WOULD JUST STALL AT REDLIGHTS WHEN I WOULD TAKE OFF,…
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I AM THE OWNER OF A 2003 CHEVY CAVALIER AND I HAVE 2 COMPLAINTS THAT SHOULD HAVE BEEN RECALLS AS THERE ARE MANY WITH THE SAME 2 PROBLEMS, FIRST EVERY GAUGE IN MY CAR QUIT WORKING NO RPM, NO GAS GUAGE AND NO SPEEDOMETER. SECOND EVER SINCE I BOUGHT MY CAR FOR NO REASON AT ALL IT WOULD JUST STALL AT REDLIGHTS WHEN I WOULD TAKE OFF, DEALER SAID NO PROBLEM, I HAVE NEARLY WRECKED MANY TIMES BECAUSE OF THIS, THE LATEST WAS TODAY I HAVE READ MANY FORUMS THAT SAY THEY FOUND OUT IT WAS THE FAULTY PLASTIC FUEL PUMP, WHY NO RECALL THIS IS GOING TO GET SOMEONE KILLED. *KB
NHTSA ODI #10410423
81,075 miles · May 7, 2011
Electrical SystemFire
I WAS DRIVING AND HAD BEEN IN MY CAR FOR ABOUT FIVE MIN AND SMOKE STARTED COMING OUT OF THE BOTTOM OF WHERE THE RADIO AND HEATER CONTROLS ARE..AT THAT TIME I PULLED OVER AND SAW FLAMES IN THE DASH AND IT WAS GROWING AND I CALLED 911 FIRE AND WE CLOSED THE DOORS AND WAITED TIL THE FIRE TRUCK GOT THERE AND HANDLED THE FIRE. IT COM…
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I WAS DRIVING AND HAD BEEN IN MY CAR FOR ABOUT FIVE MIN AND SMOKE STARTED COMING OUT OF THE BOTTOM OF WHERE THE RADIO AND HEATER CONTROLS ARE..AT THAT TIME I PULLED OVER AND SAW FLAMES IN THE DASH AND IT WAS GROWING AND I CALLED 911 FIRE AND WE CLOSED THE DOORS AND WAITED TIL THE FIRE TRUCK GOT THERE AND HANDLED THE FIRE. IT COMPLETELY DESTROYED MY DASH STEERING COLUMN FRONT WINDSHIELD AND HEAD LINER...ALL MY INSTRUMENT PANELS AND WIRING ARE FRIED. I BELIEVE IT WAS A FAULTY WIRING SYSTEM...IF NOT WOULD LIKE TO KNOW HOW THIS COULD HAVE BEEN PREVENTED AND HOW DO I FIX MY CAR.. *TR
NHTSA ODI #10399428
90,000 miles · Apr 6, 2011
Electrical System
I AM THE ORIGINAL OWNER OF A 2003 CHEVROLET CAVALIER. IT HAS 120000 MILES ON IT. A COUPLE OF YEARS AGO I NOTICED MY GAS GAGE SEEMED TO BE STUCK, THE CAR HAD APPROX 90000 MILES ON IT AT THE TIME. A COUPLE OF MONTHS LATER MY RPM GAUGE STARTED DOING THE SAME THING. ABOUT A YEAR AFTER THAT MY SPEEDOMETER STARTED TO ALSO GO HAYWI…
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I AM THE ORIGINAL OWNER OF A 2003 CHEVROLET CAVALIER. IT HAS 120000 MILES ON IT. A COUPLE OF YEARS AGO I NOTICED MY GAS GAGE SEEMED TO BE STUCK, THE CAR HAD APPROX 90000 MILES ON IT AT THE TIME. A COUPLE OF MONTHS LATER MY RPM GAUGE STARTED DOING THE SAME THING. ABOUT A YEAR AFTER THAT MY SPEEDOMETER STARTED TO ALSO GO HAYWIRE FOLLOWED BY MY OIL GAUGE. MY WHOLE INSTRUMENT CLUSTER NO LONGER WORKS. IT HAS NOT BEEN FIXED BECAUSE I CAN'T AFFORD IT AND IT HAS NOT BEEN RECALLED. BUT AFTER LOOKING AT HOW MANY CAVALIER HAVE HAD THIS SAME PROBLEM I BELIEVE IT SHOULD BE RECALLED. *TR
NHTSA ODI #10394434
NHTSA investigations
4EA07015 · Engine Stalling - Fuel Pump Failure
Opened Nov 1, 2007 · Closed Oct 28, 2008
Status: closed (inferred from source dates) · Fuel System, Gasoline; Fuel System, Gasoline:delivery; Fuel System, Gasoline:delivery:fuel Pump
ODI'S ANALYSIS OF THE STALLING INCIDENTS THAT HAVE RESULTED FROM SUBJECT COMPONENT FAILURES FOUND THAT THEY CAN OCCUR AT ANY SPEED AND GENERALLY RESULT IN A NO RESTART CONDITION.THESE ARE GENERALLY CONSIDERED TO BE FACTORS THAT INCREASE THE POTENTIAL SEVERITY OF STALLING INCIDENTS.HOWEVER, THESE INCIDENTS HAVE OCCURRED AT RELATIVELY LOW RATES IN THE SUBJECT VEHICLE POPULATION WHEN COMPARED WITH PRIOR INVESTIGATIONS INVOLVING SIMILAR CATEGORIES OF ENGINE STALL CONSEQUENCES.EVEN FOR THE EARLY MY 2003 PRODUCTION, WHERE HIGHER FAILURE RATES WERE NOTED, THE RATES OF PUMP FAILURES RESULTING IN ENGINE STALL ARE LOWER THAN RATES RECORDED IN PRIOR INVESTIGATIONS OF POPULATIONS THAT WERE NOT RECALLED.FURTHER INVESTIGATION OF THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.SEE DOCUMENT FILE FOR MORE INFORMATION ABOUT THIS CLOSING RESUME.
Additional source detail variants (3)
Fuel System, Gasoline:delivery:fuel Pump
ODI'S ANALYSIS OF THE STALLING INCIDENTS THAT HAVE RESULTED FROM SUBJECT COMPONENT FAILURES FOUND THAT THEY CAN OCCUR AT ANY SPEED AND GENERALLY RESULT IN A NO RESTART CONDITION.THESE ARE GENERALLY CONSIDERED TO BE FACTORS THAT INCREASE THE POTENTIAL SEVERITY OF STALLING INCIDENTS.HOWEVER, THESE INCIDENTS HAVE OCCURRED AT RELATIVELY LOW RATES IN THE SUBJECT VEHICLE POPULATION WHEN COMPARED WITH PRIOR INVESTIGATIONS INVOLVING SIMILAR CATEGORIES OF ENGINE STALL CONSEQUENCES.EVEN FOR THE EARLY MY 2003 PRODUCTION, WHERE HIGHER FAILURE RATES WERE NOTED, THE RATES OF PUMP FAILURES RESULTING IN ENGINE STALL ARE LOWER THAN RATES RECORDED IN PRIOR INVESTIGATIONS OF POPULATIONS THAT WERE NOT RECALLED.FURTHER INVESTIGATION OF THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.SEE DOCUMENT FILE FOR MORE INFORMATION ABOUT THIS CLOSING RESUME.
Fuel System, Gasoline:delivery
ODI'S ANALYSIS OF THE STALLING INCIDENTS THAT HAVE RESULTED FROM SUBJECT COMPONENT FAILURES FOUND THAT THEY CAN OCCUR AT ANY SPEED AND GENERALLY RESULT IN A NO RESTART CONDITION.THESE ARE GENERALLY CONSIDERED TO BE FACTORS THAT INCREASE THE POTENTIAL SEVERITY OF STALLING INCIDENTS.HOWEVER, THESE INCIDENTS HAVE OCCURRED AT RELATIVELY LOW RATES IN THE SUBJECT VEHICLE POPULATION WHEN COMPARED WITH PRIOR INVESTIGATIONS INVOLVING SIMILAR CATEGORIES OF ENGINE STALL CONSEQUENCES.EVEN FOR THE EARLY MY 2003 PRODUCTION, WHERE HIGHER FAILURE RATES WERE NOTED, THE RATES OF PUMP FAILURES RESULTING IN ENGINE STALL ARE LOWER THAN RATES RECORDED IN PRIOR INVESTIGATIONS OF POPULATIONS THAT WERE NOT RECALLED.FURTHER INVESTIGATION OF THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.SEE DOCUMENT FILE FOR MORE INFORMATION ABOUT THIS CLOSING RESUME.
Fuel System, Gasoline
ODI'S ANALYSIS OF THE STALLING INCIDENTS THAT HAVE RESULTED FROM SUBJECT COMPONENT FAILURES FOUND THAT THEY CAN OCCUR AT ANY SPEED AND GENERALLY RESULT IN A NO RESTART CONDITION.THESE ARE GENERALLY CONSIDERED TO BE FACTORS THAT INCREASE THE POTENTIAL SEVERITY OF STALLING INCIDENTS.HOWEVER, THESE INCIDENTS HAVE OCCURRED AT RELATIVELY LOW RATES IN THE SUBJECT VEHICLE POPULATION WHEN COMPARED WITH PRIOR INVESTIGATIONS INVOLVING SIMILAR CATEGORIES OF ENGINE STALL CONSEQUENCES.EVEN FOR THE EARLY MY 2003 PRODUCTION, WHERE HIGHER FAILURE RATES WERE NOTED, THE RATES OF PUMP FAILURES RESULTING IN ENGINE STALL ARE LOWER THAN RATES RECORDED IN PRIOR INVESTIGATIONS OF POPULATIONS THAT WERE NOT RECALLED.FURTHER INVESTIGATION OF THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.SEE DOCUMENT FILE FOR MORE INFORMATION ABOUT THIS CLOSING RESUME.
PE07033 · Fuel Pump Failure
Opened Jun 28, 2007 · Closed Nov 1, 2007
Status: closed (inferred from source dates) · Fuel System, Gasoline; Fuel System, Gasoline:delivery; Fuel System, Gasoline:delivery:fuel Pump
AN ENGINEERING ANALYSIS HAS BEEN OPENED TO FURTHER INVESTIGATE THE SCOPE, FREQUENCY AND POTENTIAL SAFETY-RELATED CONSEQUENCES OF THE ALLEGED DEFECT.GENERAL MOTORS (GM) HAS IDENTIFIED AN ISSUE WITH ACCELERATED MOTOR BRUSH WEAR IN THE FUEL PUMP ASSEMBLY OF MODEL YEAR (MY) 2001 THROUGH 2003 CHEVROLET VEHICLES THAT CAN CAUSE THE PUMP TO STOP OPERATING.GENERAL MOTORS INDICATED THAT PEROXIDE OR SULFUR, WHICH ARE BOTH PRESENT IN VARYING AMOUNTS IN GASOLINE, CAN REACT WITH THE COPPER COMMUTATOR OF THE PUMP MOTOR AND CORRODE/ROUGHEN THE SURFACE.A ROUGH COMMUTATOR SURFACE INCREASES THE RATE OF BRUSH WEAR.THE INCREASED ELECTRICAL RESISTANCE CAUSED BY DEGRADATION OF THE BRUSH-COMMUTATOR INTERFACE INHIBITS CURRENT FLOW THROUGH THE MOTOR WINDINGS.ACCORDING TO GM, THE CONDITION WILL USUALLY RESULT IN A NO-START CONDITION BECAUSE OF THE HIGH CURRENT REQUIRED DURING START-UP.WHEN THE ALLEGED DEFECT DOES CAUSE A STALL WHILE DRIVING INCIDENT, THE VEHICLE TYPICALLY CANNOT BE RESTARTED.GM'S ANALYSIS OF WARRANT CLAIMS SHOWED THAT NO START/HARD START WAS THE MOST COMMON CONDITION AND THE FREQUENCY OF CLAIMS ASSOCIATED WITH STALL WHILE DRIVING INCIDENTS WAS TOO LOW TO WARRANT FIELD ACTION. THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-015) TO FURTHER ASSESS THE COMPLAINT AND WARRANTY CLAIM DATA AND THE ANALYSES PROVIDED BY GM.
Additional source detail variants (3)
Fuel System, Gasoline:delivery:fuel Pump
AN ENGINEERING ANALYSIS HAS BEEN OPENED TO FURTHER INVESTIGATE THE SCOPE, FREQUENCY AND POTENTIAL SAFETY-RELATED CONSEQUENCES OF THE ALLEGED DEFECT.GENERAL MOTORS (GM) HAS IDENTIFIED AN ISSUE WITH ACCELERATED MOTOR BRUSH WEAR IN THE FUEL PUMP ASSEMBLY OF MODEL YEAR (MY) 2001 THROUGH 2003 CHEVROLET VEHICLES THAT CAN CAUSE THE PUMP TO STOP OPERATING.GENERAL MOTORS INDICATED THAT PEROXIDE OR SULFUR, WHICH ARE BOTH PRESENT IN VARYING AMOUNTS IN GASOLINE, CAN REACT WITH THE COPPER COMMUTATOR OF THE PUMP MOTOR AND CORRODE/ROUGHEN THE SURFACE.A ROUGH COMMUTATOR SURFACE INCREASES THE RATE OF BRUSH WEAR.THE INCREASED ELECTRICAL RESISTANCE CAUSED BY DEGRADATION OF THE BRUSH-COMMUTATOR INTERFACE INHIBITS CURRENT FLOW THROUGH THE MOTOR WINDINGS.ACCORDING TO GM, THE CONDITION WILL USUALLY RESULT IN A NO-START CONDITION BECAUSE OF THE HIGH CURRENT REQUIRED DURING START-UP.WHEN THE ALLEGED DEFECT DOES CAUSE A STALL WHILE DRIVING INCIDENT, THE VEHICLE TYPICALLY CANNOT BE RESTARTED.GM'S ANALYSIS OF WARRANT CLAIMS SHOWED THAT NO START/HARD START WAS THE MOST COMMON CONDITION AND THE FREQUENCY OF CLAIMS ASSOCIATED WITH STALL WHILE DRIVING INCIDENTS WAS TOO LOW TO WARRANT FIELD ACTION. THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-015) TO FURTHER ASSESS THE COMPLAINT AND WARRANTY CLAIM DATA AND THE ANALYSES PROVIDED BY GM.
Fuel System, Gasoline:delivery
AN ENGINEERING ANALYSIS HAS BEEN OPENED TO FURTHER INVESTIGATE THE SCOPE, FREQUENCY AND POTENTIAL SAFETY-RELATED CONSEQUENCES OF THE ALLEGED DEFECT.GENERAL MOTORS (GM) HAS IDENTIFIED AN ISSUE WITH ACCELERATED MOTOR BRUSH WEAR IN THE FUEL PUMP ASSEMBLY OF MODEL YEAR (MY) 2001 THROUGH 2003 CHEVROLET VEHICLES THAT CAN CAUSE THE PUMP TO STOP OPERATING.GENERAL MOTORS INDICATED THAT PEROXIDE OR SULFUR, WHICH ARE BOTH PRESENT IN VARYING AMOUNTS IN GASOLINE, CAN REACT WITH THE COPPER COMMUTATOR OF THE PUMP MOTOR AND CORRODE/ROUGHEN THE SURFACE.A ROUGH COMMUTATOR SURFACE INCREASES THE RATE OF BRUSH WEAR.THE INCREASED ELECTRICAL RESISTANCE CAUSED BY DEGRADATION OF THE BRUSH-COMMUTATOR INTERFACE INHIBITS CURRENT FLOW THROUGH THE MOTOR WINDINGS.ACCORDING TO GM, THE CONDITION WILL USUALLY RESULT IN A NO-START CONDITION BECAUSE OF THE HIGH CURRENT REQUIRED DURING START-UP.WHEN THE ALLEGED DEFECT DOES CAUSE A STALL WHILE DRIVING INCIDENT, THE VEHICLE TYPICALLY CANNOT BE RESTARTED.GM'S ANALYSIS OF WARRANT CLAIMS SHOWED THAT NO START/HARD START WAS THE MOST COMMON CONDITION AND THE FREQUENCY OF CLAIMS ASSOCIATED WITH STALL WHILE DRIVING INCIDENTS WAS TOO LOW TO WARRANT FIELD ACTION. THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-015) TO FURTHER ASSESS THE COMPLAINT AND WARRANTY CLAIM DATA AND THE ANALYSES PROVIDED BY GM.
Fuel System, Gasoline
AN ENGINEERING ANALYSIS HAS BEEN OPENED TO FURTHER INVESTIGATE THE SCOPE, FREQUENCY AND POTENTIAL SAFETY-RELATED CONSEQUENCES OF THE ALLEGED DEFECT.GENERAL MOTORS (GM) HAS IDENTIFIED AN ISSUE WITH ACCELERATED MOTOR BRUSH WEAR IN THE FUEL PUMP ASSEMBLY OF MODEL YEAR (MY) 2001 THROUGH 2003 CHEVROLET VEHICLES THAT CAN CAUSE THE PUMP TO STOP OPERATING.GENERAL MOTORS INDICATED THAT PEROXIDE OR SULFUR, WHICH ARE BOTH PRESENT IN VARYING AMOUNTS IN GASOLINE, CAN REACT WITH THE COPPER COMMUTATOR OF THE PUMP MOTOR AND CORRODE/ROUGHEN THE SURFACE.A ROUGH COMMUTATOR SURFACE INCREASES THE RATE OF BRUSH WEAR.THE INCREASED ELECTRICAL RESISTANCE CAUSED BY DEGRADATION OF THE BRUSH-COMMUTATOR INTERFACE INHIBITS CURRENT FLOW THROUGH THE MOTOR WINDINGS.ACCORDING TO GM, THE CONDITION WILL USUALLY RESULT IN A NO-START CONDITION BECAUSE OF THE HIGH CURRENT REQUIRED DURING START-UP.WHEN THE ALLEGED DEFECT DOES CAUSE A STALL WHILE DRIVING INCIDENT, THE VEHICLE TYPICALLY CANNOT BE RESTARTED.GM'S ANALYSIS OF WARRANT CLAIMS SHOWED THAT NO START/HARD START WAS THE MOST COMMON CONDITION AND THE FREQUENCY OF CLAIMS ASSOCIATED WITH STALL WHILE DRIVING INCIDENTS WAS TOO LOW TO WARRANT FIELD ACTION. THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-015) TO FURTHER ASSESS THE COMPLAINT AND WARRANTY CLAIM DATA AND THE ANALYSES PROVIDED BY GM.
EA04028 · Turn Signal Malfunction
Opened Sep 14, 2004 · Closed Nov 22, 2004
Status: closed (inferred from source dates) · Exterior Lighting:turn Signal
ON MAY 14, 2004 THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE04-043) BASED ON CONSUMER COMPLAINTS ALLEGING THAT THE BRAKE/TAIL TURN SIGNAL LAMPS WOULD NOT OPERATE PROPERLY WHEN EITHER THE TAIL LIGHTS WERE TURNED ON, THE BRAKE PEDAL WAS DEPRESSED, OR WHEN THE TURN SIGNAL SWITCH WAS ACTIVATED.ON SEPTEMBER 14, 2004 ODI UPGRADED PE 04-043 TO AN ENGINEERING ANALYSIS (EA04-028).GM STATES THAT SOME BRAKE/TAIL/TURN SIGNAL LAMP BULBS CAN PREMATURELY BECOME INOPERATIVE DUE TO EXCESSIVE HEAT BUILDUP WITHIN THE BULB SOCKETS.THE CAUSE OF THE EXCESSIVE HEAT BUILD UP WAS DETERMINED TO BE A LACK OF THERMAL GREASE PLACED IN BETWEEN THE BULB AND THE SOCKET. BY LETTER DATED OCTOBER 27, 2004 GM NOTIFIED NHTSA THAT IT WILL CONDUCT A SAFETY RECALL (NHTSA # 04V524) COVERING ALL MY 2003 VEHICLES.GM DEALERS WILL INSPECT THE REAR LAMP BULB SOCKET ASSEMBLIES AND APPLY THERMAL GREASE TO THEM OR REPLACE THEM WITH NEW ASSEMBLIES WITH THERMAL GREASE ALREADY ATTACHED.MODEL YEAR 2004 AND NEWER VEHICLES HAVE THE THERMAL GREASE INSTALLED FROM THE FACTORY. THE ACTION TAKEN BY GM IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
PE04043 · Turn Signal Malfunction
Opened May 14, 2004 · Closed Sep 14, 2004
Status: closed (inferred from source dates) · Exterior Lighting:turn Signal
COMPLAINANTS ALLEGE THAT THE REAR TURN SIGNALS FAIL TO ILLUMINATE AND DO NOT PROVIDE A SIGNAL TO DRIVERS IN FOLLOWING VEHICLES.ODI HAS RECEIVED ONE REPORT OF A CRASH WHERE THE COMPLAINANT BRAKED AND ATTEMPTED TO MAKE A LEFT TURN AND THE FOLLOWING VEHICLE IMPACTED THE COMPLAINANT'S VEHICLE IN THE DRIVER-SIDE DOOR.IN MAY 2002, GM'S SUPPLIER MADE CHANGES TO THE BULB SOCKET THAT INCLUDED STOPPING THE USE OF THERMAL-MASTIC GREASE IN THE BULB SOCKET.GM REPORTS THAT THE GREASE REDUCES ARCING AT THE CONTACTS AND DISSIPATES HEAT THUS PREVENTING MELTING OF THE SOCKET MATERIAL OR BURNING OF THE CONTACTS.MOST OF THE SUBJECT VEHICLES WERE PRODUCED WITHOUT GREASE APPLIED TO THE BULB SOCKET.IN JUNE 2003, GM DIRECTED THE SUPPLIER TO RESUME THE USE OF GREASE IN THE SOCKET.GM ISSUED TECHNICAL SERVICE BULLETIN (TSB) 04-08-42-004A ON JULY 15, 2004 ADVISING TECHNICIANS TO MAKE SURE THAT ADEQUATE AMOUNTS OF GREASE WERE ADDED TO THE BULB SOCKETS ON ALL SERVICE PARTS.ODI WILL UPGRADE THIS INVESTIGATION TO EA 04-028 TO FURTHER EXAMINE THE ISSUE.
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