IllustrationTAKATA RECALL
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
Unknown Or Other complaints
8 reports"CHECK ENGINE" LIGHT KEEPS COMING BACK ON FOR THE SAME ISSUE, SUPPOSEDLY THE "AIR INTAKE TEMP SENSOR, REPLACED THAT ONE AND SEVERAL SENSORS REPEATEDLY, HAD THE COMPLETE WIRING HARNESS CONNECTIONS CHECKED AND CLEANED, EVEN REPLACED MY ECM AND BCM [NEITHER OF WHICH WAS CHEAP], AND STILL HAS "CHECK ENGINE" LIGHT, EVEN AFTER BEING "…
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"CHECK ENGINE" LIGHT KEEPS COMING BACK ON FOR THE SAME ISSUE, SUPPOSEDLY THE "AIR INTAKE TEMP SENSOR, REPLACED THAT ONE AND SEVERAL SENSORS REPEATEDLY, HAD THE COMPLETE WIRING HARNESS CONNECTIONS CHECKED AND CLEANED, EVEN REPLACED MY ECM AND BCM [NEITHER OF WHICH WAS CHEAP], AND STILL HAS "CHECK ENGINE" LIGHT, EVEN AFTER BEING "CLEARED" OVER AND OVER AGAIN -- THIS CAR WAS WELL MAINTAINED AND THE BODY AND SUB-FRAME ARE SEVERELY ROTTING OUT LEFT AND RIGHT -- HAD A WEIRD LEAK ON THE PASS. SIDE FRONT, UNDER THE DASH. IT COMES AND GOES. THE CAR SMELLS LIKE AN OLD SNEAKER INSIDE. WATER WOULD POUR OUT OF THE PASSENGER SIDE HEATER DUCT, BUT THERE WAS NO RHYME OR REASON TO IT. ONE I EVEN HAD SOAP FOAM FROM A DRIVE THRU CAR WASH LITERALLY COME BLOWING IN TO THE CABIN, THRU THE VERY SAME HEATER DUCT. THANKFULLY IT HAS SEEMINGLY CLEARED UP, BUT IT IS STILL A HEAD SCRATCHER. I'VE TAKEN MY CAR TO SEVERAL DEALERSHIPS, PRIVATELY OWNED SHOPS, AND EVEN HAD SOME "CAR SAVVY" FRIENDS LOOK HER OVER, AS WELL AS MY DAD [ANDS ASE CERTIFIED TECH], AND THE CHECK ENGINE LIGHT STILL COMES BACK EVERY TIME. IF I WOULD HAVE KNOWN I'D PUT THIS MUCH MONEY INTO A CAR THAT LITERALLY READY TO BREAK APART, I WOULD HAVE SAVED MY MONEY TO PUT TOWARDS ANOTHER CAR. LIVE AND LEARN, I GUESS. SHE WAS DOING SO WELL FOR 10 OR 11 YEARS AND IT'S LIKE SHE JUST STARTED "GIVING UP" ON ME. SHE'S GOT 165K ON HER AND THE PAIN HAS GONE TO CRAP, BUT THAT'S GM FOR YOU, KEPT HER GARAGED, WAXED REGULARLY, HAD HER LOOKING SHOWROOM NEW, UNTIL RECENTLY, THE PAINT'S CLEAR COAT STARTED TO "STIPPLE" [SHARP BUMPS] AND BUBBLE ALL OVER TOP PANELS, STARTING WITH THE ROOF, THEN HOOD, AND NOW TRUNK. IT'S EMBARRASSING TO DRIVE HER, AND I AM NOT PAYING TO REPAINT HER, I ALREADY HAVE WAY TOO MUCH INTO A CAR THAT LIKELY WILL NOT PASS INSPECTION COMING UP IN AUGUST. I'M NOW HANDICAP'D AND DISABLED, FIXED INCOME, CAN'T AFFORD A NEW CAR.
I WAS LOOKING AT MY LOCAL NEWS STATION AND A MAN HAD CALLED THE INVESTIGATION TEAM ABOUT CRACKS IN HIS DASHBOARD SO THEY COULD GET IN TOUCH WITH GM ABOUT IT BECAUSE NOTHING WAS BEING DONE TO RESOLVE THE PROBLEM. I HAVE CRACKS IN MY DASHBOARD AND PART OF IT WAS CRACKED SO BAD IT CAME OUT AND IT IS BIG ENOUGH FOR ME TO SIT AN APPL…
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I WAS LOOKING AT MY LOCAL NEWS STATION AND A MAN HAD CALLED THE INVESTIGATION TEAM ABOUT CRACKS IN HIS DASHBOARD SO THEY COULD GET IN TOUCH WITH GM ABOUT IT BECAUSE NOTHING WAS BEING DONE TO RESOLVE THE PROBLEM. I HAVE CRACKS IN MY DASHBOARD AND PART OF IT WAS CRACKED SO BAD IT CAME OUT AND IT IS BIG ENOUGH FOR ME TO SIT AN APPLE IN. THE MAN WHO BROUGHT THE STORY TO ATTENTION WAS CONCERNED ABOUT THE CRACKS OVER THE AIRBAG THAT IF IT EVER CAME OUT THAT DEBRIS FROM THE DASHBOARD WOULD FLY EVERYWHERE AND THAT WOULD BE HAZARDOUS TO THE OCCUPANTS OF THE CAR. THIS IS A CONCERN TO ME NOW BECAUSE THE CRACKS STARTED OUT SMALL BUT GOT BIGGER OVER TIME. I'M ALMOST SURE THAT THERE WILL BE MORE CRACKS APPEARING ESPECIALLY WHEN THE WEATHER GETS HOT AND MY CAR IS NOT ALWAYS IN THE HEAT OR IN AREAS WHERE THE HOT SUN IS BEAMING DOWN ON IT. TO ME THAT WOULD BE CONSIDERED AS A DEFECT FOR THAT TO JUST HAPPEN. I ALSO HAVE A FORD ESCORT 2000 MODEL AND THE SAME THING IS HAPPENING TO THAT DASHBOARD. I CAN TAKE PHOTOS BUT I DON'T KNOW HOW TO UPLOAD THEM ON THE COMPUTER, TELL ME OTHER WAYS I CAN SEND PHOTOS IF POSSIBLE. MY VEHICLE IS MOSTLY STATIONARY AT MY HOME ADDRESS WHENEVER I AM NOT AT WORK AND I NEVER HARDLY USE THE FREEWAYS. THERE HAS DEFINITELY BEEN NO TAMPERING WITH MY VEHICLE. THE STORY I SAW ON THE NEWS WAS AIRED I BELIEVE LAST WEEK OR THE WEEK BEFORE.
THE DASHBOARD PIECES HAVE STARTED TO CRACK BAD. I REPLACED THE CONSOLE PIECE BUT THEY DONT MAKE A REPLACEMENT FOR THE STRIP ALONG THE BOTTOM OF WINDSHIELD. ITS GOT CHUNKS MISSING OUT OF IT.
TRANS AXLE WENT OUT APRIL 09 WITH A HORRIBLE MESS OF OIL, STEERING RACK REPLACED 6 MONTHS LATER, DRIVER SIDE WINDOW/ MOTOR PROBLEM, FUEL PUMP WENT 75,000 A BIT SHY OF A YEAR LATER. NOW MY DEFROST ISN'T WORKING; POSSIBLY THE SWITCH 85,000. HAD BRAKES DONE TWICE SO FAR WITH LEAKS; THIS INCLUDES HYDRAULICS, ROTORS, PADS, SHOES ET…
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TRANS AXLE WENT OUT APRIL 09 WITH A HORRIBLE MESS OF OIL, STEERING RACK REPLACED 6 MONTHS LATER, DRIVER SIDE WINDOW/ MOTOR PROBLEM, FUEL PUMP WENT 75,000 A BIT SHY OF A YEAR LATER. NOW MY DEFROST ISN'T WORKING; POSSIBLY THE SWITCH 85,000. HAD BRAKES DONE TWICE SO FAR WITH LEAKS; THIS INCLUDES HYDRAULICS, ROTORS, PADS, SHOES ETC. MY STEERING HAS SEIZED WHILE DRIVING. THIS CAR HAS BEEN A VERY EXPENSIVE INCONVENIENCE. *LN
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT THE DASHBOARD HAS STARTED TO CRACK IN 3 - 4 PLACES. SHE HAS ATTEMPTED TO NOTIFY THE DEALER, BUT HAS NOT GOTTEN A RESPONSE. THE VIN, ENGINE SIZE, AND POWERTRAIN WERE UNKNOWN. THE CURRENT MILEAGE IS 13,600 AND FAILURE MILEAGE WAS 13,000.
ALL AROUND PROBLEMS
FIRST PROBLEM WITH MY CAR WAS A SHORT IN THE BRAKE LIGHTS. CHEVROLET REPAIRED THAT. THEN THE HORN WOULD WORK RANDOMLY. CHEVROLET REPLACED THAT. THE A/C FAILED TO WORK ON THE DRIVER SIDE. CHEVROLET REPAIRED THAT. THEN THE KEYLESS ENTRY RANDOMLY STOPPED WORKING, CHEVROLET TOLD ME THEY CANNOT FIND ANYTHING WRONG THE KEYLESS ENTRY S…
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FIRST PROBLEM WITH MY CAR WAS A SHORT IN THE BRAKE LIGHTS. CHEVROLET REPAIRED THAT. THEN THE HORN WOULD WORK RANDOMLY. CHEVROLET REPLACED THAT. THE A/C FAILED TO WORK ON THE DRIVER SIDE. CHEVROLET REPAIRED THAT. THEN THE KEYLESS ENTRY RANDOMLY STOPPED WORKING, CHEVROLET TOLD ME THEY CANNOT FIND ANYTHING WRONG THE KEYLESS ENTRY STILL DOESN'T WORK PROPERLY. THEN THE CAR STARTED TURNING OFF WHILE I WAS DRIVING. CHEVROLET AGAIN TOLD ME THEY COULD NOT REPAIR THE PROBLEM DUE TO NOTHING REGISTERING ON THE COMPUTER. MY CAR TURNED OFF MID TURN AND I HIT A BRICK WALL. CHEVROLET INVESTIGATED THE ACCIDENT AND TOLD ME MY CAR DIDN'T TURN OFF. I GOT MY CAR BACK LAST TUESDAY AND MY CAR TURNED OFF AGAIN. I MADE AN APPOINTMENT TO BRING MY CAR BACK TO CHEVROLET AND ITS TURNED OFF AGAIN. I GUESS CHEVROLET WILL NEVER BE ABLE TO REPAIR MY PROBLEM. *NM
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.