IllustrationTHE STEERING WHEEL IS LOOSE. PINS ON TILT MECHANISM ARE GONE. DON'T KNOW WHEN IT FELL OUT. NOTICED WHEN CLEANING CAR WHEN I TILTED THE STEERING WHEEL UP.
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
Steering complaints
19 reportsMY CAR HAS THE SAME PROBLEM WITH THE INSTRUMENT CLUSTER THAT WAS RECALLED FOR OTHER GM VEHICLES. THE FUEL LEVEL GAUGE, TEMPERATURE GAUGE, RPM, SPEEDOMETER.... NONE OF MY GAUGES WORK. THEY GAVE THE WRONG READINGS, THE HAND WOULDN'T RETURN TO THEIR STARTING POSITIONS, THEN THE HANDS WENT LOWER THAN THEIR STARTING POSITIONS TO THE …
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MY CAR HAS THE SAME PROBLEM WITH THE INSTRUMENT CLUSTER THAT WAS RECALLED FOR OTHER GM VEHICLES. THE FUEL LEVEL GAUGE, TEMPERATURE GAUGE, RPM, SPEEDOMETER.... NONE OF MY GAUGES WORK. THEY GAVE THE WRONG READINGS, THE HAND WOULDN'T RETURN TO THEIR STARTING POSITIONS, THEN THE HANDS WENT LOWER THAN THEIR STARTING POSITIONS TO THE POINT THEY ALL DIDN'T WORK ANYMORE. THIS CAR NEEDS TO BE ADDED TO THE GM RECALL LIST FOR THE SAME PROBLEM.
INSTRUMET CLUSTER PROBLEMS FOR A FEW YEARS. FUEL SENDING UNIT HAS BEEN REPLACED AT ABOUT 52,000 MILES AFTER QUITING TWICE WHILE DRIVING HIGHWAY SPEED OF 55 MPH. DEALER CLAIMED THE CAR QUIT BECAUSE OF A BAD BATTERY THE FIRST TIME AND DID NOT DIAGNOSE THE PROBLEM CORRECTLY. IT WAS NOT THE BATTERY. THE FUEL SENDING UNIT INTERMI…
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INSTRUMET CLUSTER PROBLEMS FOR A FEW YEARS. FUEL SENDING UNIT HAS BEEN REPLACED AT ABOUT 52,000 MILES AFTER QUITING TWICE WHILE DRIVING HIGHWAY SPEED OF 55 MPH. DEALER CLAIMED THE CAR QUIT BECAUSE OF A BAD BATTERY THE FIRST TIME AND DID NOT DIAGNOSE THE PROBLEM CORRECTLY. IT WAS NOT THE BATTERY. THE FUEL SENDING UNIT INTERMITTENTLY READS WELL BEYOND FULL AND INTERFEARS WITH THE TEMPERATURE GAGE FUNCTION. NOW SPEEDOMETER IS STUCK AT 85 MPH WHILE TURNED OFF. I WAS DRIVING WITH THE CRUISE DOING 67 MPH, I SLOWED DOWN TO MAKE A TURN AT AN AT GRADE INSECTION TO A ROAD POSTED AT 55 MPH. I COMPLETED THE TURN AND SPED UP. THE SPEEDOMETER READ 58 MPH BUT IT FELT LLIKE I WAS GONG ABOUT 30 MPH. I STOPPED AT ANOTHER INTERSECTION AND THE SPEED DROPPED TO 40 MPH. I MADE THE TURN AND ACELERATED AND THE SPEED WENT TO 110 MPH BUT I WAS NOT GOING NEAR THAT FAST. THE CAR IS IN DRIVEWAY TURNED OFF BUT THE SPEEDOMETER READS 85 MPH. MOST RECENT ISSUE IS STEERING RACK AND K-FRAME RUSTED OUT AND NEEDED TO BE REPLACED. MECHANIC STATED HE NEVER SAW A STEERING RACK RUST OUT OR A K FRAME RUSTED AS BAD AS THE ONE ON THIS VEHICLE. WE ARE THE ORIGINAL OWNERS.
METAL ON METAL NOISE FOUND OUT SHOES AND ROTORS ARE DAMAGEDDAMAGED. I HAVE NO MONEY. V CAN'T FIX THIS. SMELL INSIDE OF LEAK. TEMP RUNNING HIGH. 200.
STEERING WHEEL AND SHROUD BECAME TOTALLY DISENGAGED AND FELL INTO MY LAP WHILE TRYING TO TURN ONTO LIVERNOIS ROAD MAKING IT IMPOSSIBLE FOR ME TO STEER VEHICLE.LUCKY I WAS LEAVING POST OFFICE AFTER MAILING LETTERS AND NOT WHILE ON FREEWAY. *TR
POWER SUDDENLY SHUT OFF, CAUSING POWER STEERING TO FAIL, WHICH MADE ME WRECK INTO A DITCH. IT ALSO CAUSED THE AIRBAGS TO NOT DEPLOY AND PREVENTED SEATBELTS FROM LOCKING INTO PLACE WHEN THE BRAKES WERE HIT. *TR
I HAD BEEN READING ABOUT RECENT RECALLS WITH GM, ESPECIALLY IGNITION SWITCHES. I HAVE A 2003 CHEVY CAVALIER AND IT WAS DIAGNOSED WITH A BAD IGNITION SWITCH. I FIRST NOTICED WHEN I WENT TO START THE CAR IN THE MORNING, A DAY AFTER COMING HOME FROM WORK. GOOD THING IT HAPPENED THEN BECAUSE I WOULD HAVE BEEN STRANDED OFF SITE. …
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I HAD BEEN READING ABOUT RECENT RECALLS WITH GM, ESPECIALLY IGNITION SWITCHES. I HAVE A 2003 CHEVY CAVALIER AND IT WAS DIAGNOSED WITH A BAD IGNITION SWITCH. I FIRST NOTICED WHEN I WENT TO START THE CAR IN THE MORNING, A DAY AFTER COMING HOME FROM WORK. GOOD THING IT HAPPENED THEN BECAUSE I WOULD HAVE BEEN STRANDED OFF SITE. I WENT TO START THE CAR, NOTHING HAPPENED EXCEPT WIPERS AND RADIO DID NOT WORK AS WELL WHICH I THOUGHT WAS STRANGE. FINALLY THE RADIO AT LEAST CAME ON AT SOME POINT, BUT CAR STILL WOULD NOT START. AFTER IT WAS FIXED THEY SAID THE IGNITION SWITCH WAS BAD AND THE MECHANIC ASKED IF I HAD LOOKED FOR THE RECALL ON IT. I SEARCHED ONLINE BUT DID NOT FIND IT. I KNOW MY CAR IS OLDER, HOWEVER OF ALL THE CARS I EVER OWNED AND I HAD MANY, I NEVER HAD ANY ISSUES WITH IGNITION SWITCHES! I THINK I HAD ONE OF THE DEFECTIVE SWITCHES AND WOULD LIKE TO LOOK INTO THIS MATTER. UNFORTUNATELY I PROBABLY CAN'T GO BACK TO GET THE PHYSICAL IGNITION SWITCH AT THIS POINT, TOO LATE. I HAVE THE PROPER PAPERWORK FOR IT HOWEVER. ALSO ON ANOTHER NOTE, MY REAR DRIVER SIDE SIGNAL KEEPS GOING OUT, NO MATTER HOW MANY TIMES I REPLACE IT. THAT MIGHT BE SOMETHING GM SHOULD LOOK INTO AS WELL. *TR
2006 CHEVROLET COBALT & 2003 CAVALIER. CONSUMER WRITES IN REGARDS TO BOTH VEHICLES POWER STEERING AND CUTTING OFF PROBLEMS. *SMD THE CONSUMER STATED THE CAVALIER, CUT OFF, JUST LIKE THE COBALT. HOWEVER, THE COBALT WAS RECALLED. THE CAVALIER CUT OFF WEEKLY SINCE IT WAS PURCHASED. THE POWER STEERING WAS REPLACED DURING A RECA…
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2006 CHEVROLET COBALT & 2003 CAVALIER. CONSUMER WRITES IN REGARDS TO BOTH VEHICLES POWER STEERING AND CUTTING OFF PROBLEMS. *SMD THE CONSUMER STATED THE CAVALIER, CUT OFF, JUST LIKE THE COBALT. HOWEVER, THE COBALT WAS RECALLED. THE CAVALIER CUT OFF WEEKLY SINCE IT WAS PURCHASED. THE POWER STEERING WAS REPLACED DURING A RECALL. IT WAS REPLACED AT 35,000 MILES AND AGAIN AT 68,000. *JB UPDATED 08/07/14 *JB UPDATED 09/24/14. *JB
MY SON WAS PULLING INTO A PARKING LOT AND AS HE DESCRIBES IT, EVERYTHING BUT THE RADIO WENT DEAD ALL BY ITSELF (THE ENGINE DIED AND THERE WAS NO POWER STEERING OR BRAKES). OBVIOUSLY THE SAME SYMPTOMS AS THE CURRENT RECALLS. I CALLED THE DEALER AND WAS TOLD THE CAR ISN'T ON THE LIST. I'VE COMPLAINED TO CHEVY AND AM GETTING THE…
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MY SON WAS PULLING INTO A PARKING LOT AND AS HE DESCRIBES IT, EVERYTHING BUT THE RADIO WENT DEAD ALL BY ITSELF (THE ENGINE DIED AND THERE WAS NO POWER STEERING OR BRAKES). OBVIOUSLY THE SAME SYMPTOMS AS THE CURRENT RECALLS. I CALLED THE DEALER AND WAS TOLD THE CAR ISN'T ON THE LIST. I'VE COMPLAINED TO CHEVY AND AM GETTING THE RUNAROUND BY MULTIPLE MEMBERS OF THEIR "CONSUMER SUPPORT TEAM" (WE'VE ASSIGNED YOU A SERVICE REQUEST NUMBER BUT I AM TO WAIT UNTIL IT HAPPENS AGAIN AND THEN BRING IT IN "SO WE COULD START REVIEWING ON YOUR CASE"). I TOOK IT TO MY OWN MECHANIC AND HE RAN A BUNCH OF TESTS BUT COULDN'T FIND ANYTHING THAT WOULD CAUSE THE CAR TO DIE. *TR
DRIVING AT LOW SPEED. STEERING WHEEL EXPERIENCED EXCESSIVE SIDE PLAY. MADE APPOINTMENT AT LOCAL MECHANIC (NON-DEALER) STEERING HOUSING TAKEN OFF AND FOUND ONE OF TWO PINS IN THE STEERING COLUMN FOR THE TILT MECHANISM HALF WAY OUT OF HOUSING. MECHANIC REINSERTED PIN AND ATTEMPTED TO RESTAKE PIN IN HOUSING. EXPERIENCED NO SIDE P…
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DRIVING AT LOW SPEED. STEERING WHEEL EXPERIENCED EXCESSIVE SIDE PLAY. MADE APPOINTMENT AT LOCAL MECHANIC (NON-DEALER) STEERING HOUSING TAKEN OFF AND FOUND ONE OF TWO PINS IN THE STEERING COLUMN FOR THE TILT MECHANISM HALF WAY OUT OF HOUSING. MECHANIC REINSERTED PIN AND ATTEMPTED TO RESTAKE PIN IN HOUSING. EXPERIENCED NO SIDE PLAY AFTER REPAIR FOR ABOUT 1 WEEK AND PROBLEM HAS RESURFACED. *TR
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.