IllustrationWHEN THE BRAKES ARE APPLIED VEHICLE SHAKES. CONSUMER STATES THAT THE ROTORS ARE THE CAUSE OF THE PROBLEM. *AK
2003 Chevrolet Cavalier
Owner reports · Recalls · Investigations
More warning signs than most Cavalier years
Owner complaints for the 2003 Chevrolet Cavalier are substantially higher than the model-year median of 140.
About this comparison →How this year compares
Owner complaints by model year
Compare all Cavalier years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
810–25K
9225–50K
19750–75K
10875–100K
58100–150K
17150K+
553 reports with mileage · 125 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Fuel System, Gasoline. Review the 340 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 106 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Exterior Lighting. Review the 57 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
31 crash reports6 fire reports16 injury reports
Service Brakes, Hydraulic complaints
30 reportsWHEN APPLYING THE BRAKES AT NIGHT, THE HEADLIGHTS AND DASH LIGHTS DIM TO A SOFTER SHADE OF LIGHT. I HAVE ALSO CHANGED THE REAR SINGLE LIGHTS IN MY CAR THREE TIMES IN THE PAST 6 MONTHS. THIS CAR HAS A BAD BRAKE PROBLEM. THE FRONT OF THE CAR SHAKES VERY BAD WHEN YOU APPLY THE BRAKES WHILE EXITING A HIGHWAY. CITY DRIVING IS NOT …
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WHEN APPLYING THE BRAKES AT NIGHT, THE HEADLIGHTS AND DASH LIGHTS DIM TO A SOFTER SHADE OF LIGHT. I HAVE ALSO CHANGED THE REAR SINGLE LIGHTS IN MY CAR THREE TIMES IN THE PAST 6 MONTHS. THIS CAR HAS A BAD BRAKE PROBLEM. THE FRONT OF THE CAR SHAKES VERY BAD WHEN YOU APPLY THE BRAKES WHILE EXITING A HIGHWAY. CITY DRIVING IS NOT AS BAD, BUT WHEN THE BRAKES GET WARMED UP THEY PULSATE WHEN I COME TO A STOP. AT THE END OF THE DAY, I PULL MY CAR INTO MY DRIVEWAY AND THE FIRST THING I SMELL WHEN I GET OUT IS A BURNING SMELL FROM THE BACK BRAKES. I CALLED THE FUCILLO CHEVY SERVICE DEPARTMENT IN DECEMBER 2003. I TALKED TO A SERVICEMAN ABOUT MY BRAKE PROBLEM. HE TOLD ME THAT MY PULSATING BRAKES IS THE ABS SYSTEM WORKING IN THE SNOW. NOW THE ROADS ARE DRY AND MY BRAKES ARE STILL PULSATING. I COULD NOT FIND ANYTHING IN MY ORIGINAL PAPERWORK ON MY CAR SHOWING THAT IT HAS THE ABS SYSTEM. NOW MY BRAKES ARE SHOT. THE CAR HAD ONLY 6500 HUNDRED MILES ON IT WHEN I FIRST CALLED IN DECEMBER OF 2003. IN JUNE OF 2003, I BOUGHT THIS CAR AND TEST DROVE IT. THE CAR SEEMED TO BE A GOOD CAR, EXCEPT FOR THE NOISE THAT I HEARD COMING FROM THE FRONT LEFT TIRE AREA. IT SOUNDED LIKE A RUBBER BAND WHEN IT SNAPS. I BROUGHT IT UP TO MY SALESMEN ROCKY FROM THE CHEVY DEPARTMENT. HE TOLD ME THAT IT'S A NEW CAR. NOW WHEN THE FRONT TIRES ARE TURNED TO THE RIGHT, IT MAKES A CRUNCHING NOISE. WHEN I DRIVE OVER ANY BUMP AT ANY SPEED, IT FEELS LIKE THERE ARE NO SHOCKS OR STRUTS ON THIS CAR AND MAKES A BAD CLUNKING SOUND. *NM
1. BOTH BRAKE LIGHTS WENT OUT W/IN MONTH OF EACH OTHER. IN THE MONTHS OF JULY AND AUGUST. 2. BRAKES NOISY, SEPTEMBER 3. TRUNK WOULD NOT OPEN, OCTOBER 4. BRAKES NOISY, AGAIN, NOVEMBER 5. CAR TURNS OFF IN THE MIDDLE OF AN INTERSECTION AFTER MAKING A COMPLETE STOP AND TRYING TO SPEED UP. FREAKING OUT, I PRESSED THE GAS AND MOVED TH…
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1. BOTH BRAKE LIGHTS WENT OUT W/IN MONTH OF EACH OTHER. IN THE MONTHS OF JULY AND AUGUST. 2. BRAKES NOISY, SEPTEMBER 3. TRUNK WOULD NOT OPEN, OCTOBER 4. BRAKES NOISY, AGAIN, NOVEMBER 5. CAR TURNS OFF IN THE MIDDLE OF AN INTERSECTION AFTER MAKING A COMPLETE STOP AND TRYING TO SPEED UP. FREAKING OUT, I PRESSED THE GAS AND MOVED THE KEY IN THE IGNITION, THEN PUT CAR IN PARK AND GOT IT TO START, NOVEMBER. IT JUST SEEMS TO ME THAT I HAVE A DISFUNCTIONAL CAR THAT WHEN I DONT HAVE SOMETHING WRONG WITH ONE THING I HAVE TO GO IN TO THE DEALER FOR ANOTHER. ITS A NEW CAR AND ITS COSTING ME MORE PROBLMES AND INCONVINIENCES THAN THE OLD '96 I HAD TILL I BOUGHT THIS ONE.
I HAVE A MAJOR PROBLEM WITH A VEHICLE THAT I RECENTLY PURCHASED. I BOUGHT A 2003 CAVALIER AND THERE WAS A PROBLEM WITH IT LAST WEEK. I NEED TO KNOW EXACTLY WHO TO TALK TO BEFORE I TAKE ANY FURTHER ACTIONS. MY CAR IS SUPPOSED TO HAVE AN EXTENDED WARRANTY ON IT AND I KNOW THAT I'M SUPPOSED TO BE ABLE TO GET A RENTAL CAR. WELL…
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I HAVE A MAJOR PROBLEM WITH A VEHICLE THAT I RECENTLY PURCHASED. I BOUGHT A 2003 CAVALIER AND THERE WAS A PROBLEM WITH IT LAST WEEK. I NEED TO KNOW EXACTLY WHO TO TALK TO BEFORE I TAKE ANY FURTHER ACTIONS. MY CAR IS SUPPOSED TO HAVE AN EXTENDED WARRANTY ON IT AND I KNOW THAT I'M SUPPOSED TO BE ABLE TO GET A RENTAL CAR. WELL, HERE'S THE SITUATION LAST WEEK, I WAS DRIVING MY CAR AND WENT TO MAKE A TURN AND MY STEERING WHEEL LOCKED UP WHILE I WAS DRIVING. I WAS ON THE WAY TO TAKE IT TO BE LOOKED AT AND IT HAPPPENED AGAIN, BUT WHEN I TRIED TO STOP, THE CAR JUST KEPT GOING AND CAUSED ME TO CRASH INTO ANOTHER VEHICLE. WHEN I WENT TO THE DEALERSHIP TO SPEAK TO SOMEONE, THEY OFFERED NO HELP AS FAR AS MY RENTAL AND WARRANTY. I AM ANGRY BECAUSE THIS FLAW WITH THE CAR COULD'VE RESULTED IN MY DEATH. IT TOOK OVER A MONTH TO GET SOMEONE TO COME TAKE A LOOK AT THE CAR AND WHEN SOMEONE FINALLY CAME ON NOV. 2, THEY SAID THEY DIDN'T FIND ANYTHING WRONG AND THAT WAS IT. I TRIED MAKING CONTACT AGAIN AND GOT NO RESPONSE. I'M STILL WITHOUT MY VEHICLE BECAUSE EVEN IF I PAY TO HAVE IT REPAIRED, THERE IS STILL THE CHANCE THAT IT COULD HAPPEN AGAIN.*AK
A DARK BROWN RUST COLOR DEVELOPED ON THE FRONT WHEELS. THE DEALERSHIP IN AN ATTEMPT TO CORRECT THE PROBLEM, CHANGED THE BRAKES, TURNED THE ROTOR AND PUT NEW BEARINGS ON, BUT THE PROBLEM STILL EXIST. THE DEALERSHIP INDICATED THAT THE BROWN RUST COLOR WAS CAUSED BY A FAILURE IN THE BRAKE SYSTEM. *JB
GRINDING NOISE IN THE BRAKING SYSTEM WHEN BRAKES ARE APPLIED. HAVE HAD THE CAR BACK TO THE DEALER FOR SERVICE TWICE. THE SECOND TIME SERVICE MANAGER STATED THAT GM WAS WELL AWARE OF THE PROBLEM, THAT ALL CAVALIERS HAVE IT AND THERE IS NOTHING THEY CAN DO ABOUT IT. SERVICE MANAGER STATED THAT IT WAS CAUSED BY "TRAVEL" IN THE CA…
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GRINDING NOISE IN THE BRAKING SYSTEM WHEN BRAKES ARE APPLIED. HAVE HAD THE CAR BACK TO THE DEALER FOR SERVICE TWICE. THE SECOND TIME SERVICE MANAGER STATED THAT GM WAS WELL AWARE OF THE PROBLEM, THAT ALL CAVALIERS HAVE IT AND THERE IS NOTHING THEY CAN DO ABOUT IT. SERVICE MANAGER STATED THAT IT WAS CAUSED BY "TRAVEL" IN THE CALIPERS.*AK
WHILE DRIVING AT ANY SPEED AND WHENEVER THE CONSUMER DEPRESSED THE BRAKE PEDAL VEHICLE LOST POWER. ALSO, INTERMITTENTLY CRUISE CONTROL ENGAGED ON ITS OWN. VEHICLE WOULD HAVE TO BE TURNED OFF TO DISENGAGE IT. VEHICLE WAS TAKEN TO DEALER SEVERAL TIMES, AND THE DEALER COULD NOT FIND THE CAUSES OF THE PROBLEMS.*AK
BRAKE PEDAL ON THIS CAR IS MUCH HIGHER THAN ACCELERATOR PEDAL. UNTIL THE DRIVER GETS USED TO THE HEIGHT MISMATCH, THE DRIVER'S FOOT HITS THE SIDE OF THE BRAKE PEDAL WHEN TRYING TO APPLY THE BRAKES. THIS IS VERY DANGEROUS SINCE THIS WILL CAUSE A HUGE LAG IN RESPONSE TIME IN BRAKING.I CALLED THE LOCAL CHEVROLET SERVICE AND THEY …
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BRAKE PEDAL ON THIS CAR IS MUCH HIGHER THAN ACCELERATOR PEDAL. UNTIL THE DRIVER GETS USED TO THE HEIGHT MISMATCH, THE DRIVER'S FOOT HITS THE SIDE OF THE BRAKE PEDAL WHEN TRYING TO APPLY THE BRAKES. THIS IS VERY DANGEROUS SINCE THIS WILL CAUSE A HUGE LAG IN RESPONSE TIME IN BRAKING.I CALLED THE LOCAL CHEVROLET SERVICE AND THEY SAID THERE WAS NOT AN ADJUSTMENT FOR EITHER PEDAL (LOWER THE BRAKE OR RAISE THE ACCELERATOR PEDAL).*AK
WHEN APPLYING THE BRAKES, THE PEDAL GOES TO THE FLOOR, ACCOMPANIED BY A GRINDING NOISE. *AK. ALSO THE PASSENGER SEAT BELT RETRACTOR WAS REPLACED PH. *JB
THE BRAKES GRIND/SQUEAKED WHEN USED FOR THE FIRST TIME EACH DAY. THE BRAKES WERE ALSO SENSITIVE AND GRABBED ON OCCASION. THE SERVICE TECHNICIAN INDICATED THAT THIS WAS NORMAL OPERATION. *NLM *NLM
Official recalls
104V524000 · Exterior Lighting:turn Signal
Nov 1, 2004
ON CERTAIN PASSENGER VEHICLES, THE REAR LAMPS THAT PROVIDE STOP AND TURN SIGNALS AND TAIL LAMP FUNCTIONS STOP WORKING BECAUSE OF INADEQUATE CONTACT BETWEEN THE BULB AND SOCKET. IN ADDITION, IF ONE BULBS WERE TO BECOME INOPERATIVE WHILE THE VEHICLE WAS OPERATING IN CRUISE CONTROL, THE CRUISE CONTROL WOULD DISENGAGE WHEN THE REMAINING BULB WAS ACTIVATED. IF BOTH LAMPS WERE TO BECOME INOPERATIVE, THE CRUISE CONTROL WOULD NOT ENGAGE.
Consequence & remedy
Consequence: AN INOPERATIVE BRAKE LAMP WILL NOT CONVEY THE DRIVER'S INTENTION OF STOPPING TO DRIVERS IN FOLLOWING VEHICLES, AND AN INOPERATIVE REAR TURN SIGNAL LAMP WILL NOT CONVEY THE DRIVER'S INTENTION TO TURN TO DRIVERS IN FOLLOWING VEHICLES. BOTH OF THESE FAILURES CAN INCREASE THE RISK OF A CRASH.
Remedy: DEALERS WILL INSPECT THE REAR LAMP BULB SOCKET ASSEMBLIES AND APPLY GREASE OR REPLACE THEM IF NECESSARY. THE RECALL BEGAN ON JANUARY 18, 2005. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438 OR PONTIAC AT 1-800-620-7668.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
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.