NHTSA owner reports · September 18, 2026 snapshot.
Electrical System complaints
106 reportsClear category filter68,244 miles · Jan 28, 2011
Electrical System
TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT THE INSTRUMENT CLUSTER PANEL FAILED WHILE DRIVING 35 MPH. THE VEHICLE WAS TAKEN TO THE DEALER WHO STATED THAT THE PARTS NEEDED FOR REPAIRS WOULD TAKE TWO WEEKS TO BECOME AVAILABLE. THE MANUFACTURER WAS CONTACTED AND OFFERED NO ASSISTANCE. THE FAILURE MILEAGE…
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TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT THE INSTRUMENT CLUSTER PANEL FAILED WHILE DRIVING 35 MPH. THE VEHICLE WAS TAKEN TO THE DEALER WHO STATED THAT THE PARTS NEEDED FOR REPAIRS WOULD TAKE TWO WEEKS TO BECOME AVAILABLE. THE MANUFACTURER WAS CONTACTED AND OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS 68,244.
NHTSA ODI #10379419
70,000 miles · Jan 19, 2011
Electrical System
SPEEDOMETER REGISTERS OVER 120 MILES AND BEYOND EVEN WHEN STOPPED. *TR
NHTSA ODI #10377178
115,000 miles · Dec 22, 2010
Electrical System
VEHICLE INSTRUMENT PANEL CLUSTER NO LONGER WORKS ACCURATELY. STARTED WITH TACHOMETER BUT NOW EFFECT ALL GAUGES - FUEL, SPEEDOMETER, TACHOMETER AND TEMPERATURE. ELECTRICAL OUTLET ON DRIVER SIDE ALSO DOESN'T WORK AND DOME LIGHT TURNS ON SPORADICALLY. THE FAILURE IS NOW CONSTANT AND I AM UNABLE TO TELL HOW MUCH FUEL I HAVE, IF MY …
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VEHICLE INSTRUMENT PANEL CLUSTER NO LONGER WORKS ACCURATELY. STARTED WITH TACHOMETER BUT NOW EFFECT ALL GAUGES - FUEL, SPEEDOMETER, TACHOMETER AND TEMPERATURE. ELECTRICAL OUTLET ON DRIVER SIDE ALSO DOESN'T WORK AND DOME LIGHT TURNS ON SPORADICALLY. THE FAILURE IS NOW CONSTANT AND I AM UNABLE TO TELL HOW MUCH FUEL I HAVE, IF MY VEHICLE IS OVERHEATING OR HOW FAST I AM TRAVELING. I WILL HAVE TO REPLACE THE ENTIRE PANEL TO THE COST OF $800! *TR
NHTSA ODI #10372033
63,000 miles · Dec 17, 2010
Electrical System
WHILE IN PARK MY 2003 CAVALIER TACHOMETER READS AT 5 RPM WHILE DRIVING AT 30MPH MY TACHOMETER READS OVER 7 RPMS. THE ENGINE SOUNDS NORMAL CONTACTED CHEVY AND WAS TOLD THEY DID NOT HAVE ENOUGH COMPLAINTS TO DO A RECALL WHEN IT IS A SAFETY ISSUE IT SHOULD NOT MATTER THE NUMBER OF COMPLAINTS I CAN NOT AFFORD TO PAY 500 TO FIX THIS…
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WHILE IN PARK MY 2003 CAVALIER TACHOMETER READS AT 5 RPM WHILE DRIVING AT 30MPH MY TACHOMETER READS OVER 7 RPMS. THE ENGINE SOUNDS NORMAL CONTACTED CHEVY AND WAS TOLD THEY DID NOT HAVE ENOUGH COMPLAINTS TO DO A RECALL WHEN IT IS A SAFETY ISSUE IT SHOULD NOT MATTER THE NUMBER OF COMPLAINTS I CAN NOT AFFORD TO PAY 500 TO FIX THIS WITH NO GUARANTEE IT WILL WORK. *TR
NHTSA ODI #10371122
88,478 miles · Dec 11, 2010
Electrical SystemFuel System, Gasoline
DRIVING AT 60 MPH JUST DIED ON THE INTERSTATE,PULLED OVER STARTED BACK UP ALSO AT 60,000 MILES FUEL PUMP WENT OUT NOTHING BUT PROBLEMS WITH THIS 2003 CAVALIER THEY ARE A LEMON,WHY ISN'T SOMETHING DONE????? BEFORE SOMEONE GETS KILLED IF THEY HAVEN'T ALREADY!! *TR
NHTSA ODI #10369977
80,000 miles · Dec 10, 2010
Electrical System
ABOUT A YEAR AGO, MY SPEEDOMETER WENT CRAZY (~80,000 MILES), AND A FEW DAYS AGO MY FUEL GAUGE FOLLOWED SUIT (117,000 MILES). I SAW THE SAME PROBLEM WIDELY MENTIONED ON THE INTERNET, INCLUDING AN ACTUAL RECALL ON THE TRUCKS WHICH USE THE SAME INSTRUMENT CLUSTER. DEALER SAID REPAIRS WOULD BE $300-$500 WHICH I COULDN'T AFFORD, SO…
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ABOUT A YEAR AGO, MY SPEEDOMETER WENT CRAZY (~80,000 MILES), AND A FEW DAYS AGO MY FUEL GAUGE FOLLOWED SUIT (117,000 MILES). I SAW THE SAME PROBLEM WIDELY MENTIONED ON THE INTERNET, INCLUDING AN ACTUAL RECALL ON THE TRUCKS WHICH USE THE SAME INSTRUMENT CLUSTER. DEALER SAID REPAIRS WOULD BE $300-$500 WHICH I COULDN'T AFFORD, SO I JUST USED THE TACHOMETER TO GAUGE MY ROADSPEED. CAN'T LIVE WITHOUT THE FUEL GAUGE THOUGH. *TR
NHTSA ODI #10369869
82,100 miles · Dec 2, 2010
Electrical System
I HAVE A 2003 CHEVROLET CAVALIER THAT IS ON IT'S SECOND INSTRUMENT CLUSTER AND NOW IT HAS GONE BAD, NO SPEEDOMETER, NO FUEL GAUGE AND NO TEMPERATURE. I'VE RESEARCHED THIS PROBLEM AND THERE ARE HUNDREDS OF COMPLAINTS LIKE THIS. IF GM IS IN SUCH GREAT SHAPE AS RECENTLY REPORTED, THEN WHY CAN'T YOUR ORGANIZATION INSTRUCT THEM TO MA…
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I HAVE A 2003 CHEVROLET CAVALIER THAT IS ON IT'S SECOND INSTRUMENT CLUSTER AND NOW IT HAS GONE BAD, NO SPEEDOMETER, NO FUEL GAUGE AND NO TEMPERATURE. I'VE RESEARCHED THIS PROBLEM AND THERE ARE HUNDREDS OF COMPLAINTS LIKE THIS. IF GM IS IN SUCH GREAT SHAPE AS RECENTLY REPORTED, THEN WHY CAN'T YOUR ORGANIZATION INSTRUCT THEM TO MAKE GOOD ON THE SAFETY OF THEIR VEHICLES? I CAN'T SELL THE VEHICLE BECAUSE NO ONE WANTS TO BUY A VEHICLE THAT THEY HAVE NO IDEA OF HOW FAST THEY ARE GOING OR HOW MUCH FUEL IS IN THE TANK. *TR
NHTSA ODI #10368631
60,000 miles · Nov 29, 2010
Electrical System
MY SPEEDOMETER BEGAN OPERATING ERRATICALLY ABOUT 1 YEAR AGO FOR THE LAST 3 MONTHS IT HAS NOT OPERATED AT ALL STAYS BELOW 0 AT ALL TIMES. *TR
NHTSA ODI #10368260
Mileage unknown · Sep 22, 2010
Electrical SystemFuel System, OtherVisibility
2003 CAVALIER, THE DEFROSTER KNOB CABLE HAS GONE BAD 2X'S BEFORE IT IS GONE AGAIN, THE DRIVER SIDE WINDOW MOTOR WENT LAST YEAR, LAST MONTH THE FUEL PUMP WENT, THE PASSENGER SIDE MOTOR IS GOING, THE SPEEDOMETER IS MESSED UP ALONG WITH THE TACK, IT STICKS. MY DAUGHTER DRIVES THIS CAR JUST TURNED 17, THE SPEEDOMETER SAID SHE WAS …
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2003 CAVALIER, THE DEFROSTER KNOB CABLE HAS GONE BAD 2X'S BEFORE IT IS GONE AGAIN, THE DRIVER SIDE WINDOW MOTOR WENT LAST YEAR, LAST MONTH THE FUEL PUMP WENT, THE PASSENGER SIDE MOTOR IS GOING, THE SPEEDOMETER IS MESSED UP ALONG WITH THE TACK, IT STICKS. MY DAUGHTER DRIVES THIS CAR JUST TURNED 17, THE SPEEDOMETER SAID SHE WAS GOING 105, WHEN SHE SHUTS THE CAR OFF IT SAYS SHE'S STILL DOING 35, AT TIMES THE CAR WONT START, DON'T KNOW EXACTLY WHY, THIS IS BS, THERE IS ONLY 72000 MILES ON IT, GM NEEDS TO START FIXING THESE PROBLEMS, SOME ONE IS GOING TO GET KILLED. *TR
NHTSA ODI #10357087
Mileage unknown · Sep 16, 2010
Electrical System
MY ENTIRE INSTRUMENT PANEL ON MY 2003 CHEVY CAVALIER HAS STOPPED WORKING. FIRST IT WAS THE GAS GAUGE THAT STOPPED ABOUT 2 YEARS AGO. I JUST LEARNED TO LIVE IT. THEN RECENTLY MY SPEEDOMETER AND RPM METER STOPPED WORKING AS WELL. I HAVE HAD MULTIPLE PRICE ESTIMATES DONE AND NONE HAVE BEEN UNDER $500 AND I JUST PLAIN AND SIMPLE CAN…
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MY ENTIRE INSTRUMENT PANEL ON MY 2003 CHEVY CAVALIER HAS STOPPED WORKING. FIRST IT WAS THE GAS GAUGE THAT STOPPED ABOUT 2 YEARS AGO. I JUST LEARNED TO LIVE IT. THEN RECENTLY MY SPEEDOMETER AND RPM METER STOPPED WORKING AS WELL. I HAVE HAD MULTIPLE PRICE ESTIMATES DONE AND NONE HAVE BEEN UNDER $500 AND I JUST PLAIN AND SIMPLE CAN'T AFFORD TO HAVE IT DONE WHILE I'M CURRENTLY UNEMPLOYED. I HAVE RESEARCHED OTHER CASES OF FAULTY INSTRUMENT PANEL AND THERE ARE LITERALLY THOUSANDS OF COMPLAINTS ON GM MODELS INCLUDING THE CAVALIER. THIS IS CERTAINLY NOT SAFE AND I'M ASSUMING IT'S ILLEGAL TO DRIVE WITHOUT A SPEEDOMETER BUT STILL AFTER YEARS OF COMPLAINTS TO GM OF FAULTY INSTRUMENT PANELS THERE HAS BEEN NO RECALL. *TR
NHTSA ODI #10355992
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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