NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
678 reports60,000 miles · Jul 9, 2009
Fuel System, Gasoline
MY 19 YEAR OLD DAUGHTER DURING REGULAR DRIVING FROM WORK, CAR JUST DIED ON THE HIGHWAY. CAR HAS 60,000 MILES ON IT TURNS OUT TO BE THE FUEL PUMP AND AFTER RESEARCHING THE REMOVAL PROCESS.I NOTICED THAT EVERY CAVALIER FROM 01 ON HAS THE SAME ISSUE WITH THE FUEL PUMP. THIS IS OBVIOUSLY A MANUFACTURE DEFECT AND SHOULD BE RECALLE…
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MY 19 YEAR OLD DAUGHTER DURING REGULAR DRIVING FROM WORK, CAR JUST DIED ON THE HIGHWAY. CAR HAS 60,000 MILES ON IT TURNS OUT TO BE THE FUEL PUMP AND AFTER RESEARCHING THE REMOVAL PROCESS.I NOTICED THAT EVERY CAVALIER FROM 01 ON HAS THE SAME ISSUE WITH THE FUEL PUMP. THIS IS OBVIOUSLY A MANUFACTURE DEFECT AND SHOULD BE RECALLED IMMEDIATELY. *TR
NHTSA ODI #10276291
86,300 miles · Jul 3, 2009
Engine And Engine CoolingFuel System, Gasoline
I OWN A 2003 CHEVROLET CAVALIER LS SEDAN WITH APPROXIMATELY 86,300 MILES ON IT. WITHOUT WARNING THE CAR DIED AND WOULD NOT START ON A BUSY JULY 4TH WEEKEND ALONG I-55 NORTH BOUND NEAR LITICHFIELD, IL. I T WOULD NOT RESTART, AND SUBSEQUENT INVESTIGATION RESULTED IN THE FACT FINDING THAT IT WAS THE FUEL PUMP. APPARENTLY THIS IS A …
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I OWN A 2003 CHEVROLET CAVALIER LS SEDAN WITH APPROXIMATELY 86,300 MILES ON IT. WITHOUT WARNING THE CAR DIED AND WOULD NOT START ON A BUSY JULY 4TH WEEKEND ALONG I-55 NORTH BOUND NEAR LITICHFIELD, IL. I T WOULD NOT RESTART, AND SUBSEQUENT INVESTIGATION RESULTED IN THE FACT FINDING THAT IT WAS THE FUEL PUMP. APPARENTLY THIS IS A MAJOR PROBLEM WITH THIS MAKE AND MODEL VEHICLE. I REQUEST THAT GM BE REQUIRED TO RECALL THIS MAKE AND MODEL TO ADDRESS THE PROBLEM AND REIMBURSE OWNERS FOR OUT OF POCKET EXPENSES. I HAVE ALWAYS OWNED AMERICAN CARS, BUT AN SERIOUS CONSIDERING A TOYOTA NEXT YEAR. *TR
NHTSA ODI #10275695
61,006 miles · Jun 19, 2009
Fuel System, Gasoline
MY 2003 CHEVROLET CAVALIER WITH ~61000 MILES NEEDS A NEW FUEL PUMP; A FUEL PUMP SHOULD LAST MUCH LONGER THAN THAT. *TR
NHTSA ODI #10274340
85,000 miles · Jun 18, 2009
Fuel System, Gasoline
MY CAVALIER RAN PERFECTLY UNTIL THE OTHER DAY WHEN MY HUSBAND TRIED TO START IT AND IT WOULD START AND THE DIE. HE TRIED STARTING IT A COUPLE OF TIMES. SOMETIMES IT WOULDN'T START AND THEN SOMETIMES IT WOULD START THEN DIE. THE FUEL PUMP HAD TO BE REPLACED. MY CAR HAS 85,000 MILES ON IT AND I BOUGHT IT WITH A SALVAGE TITLE I…
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MY CAVALIER RAN PERFECTLY UNTIL THE OTHER DAY WHEN MY HUSBAND TRIED TO START IT AND IT WOULD START AND THE DIE. HE TRIED STARTING IT A COUPLE OF TIMES. SOMETIMES IT WOULDN'T START AND THEN SOMETIMES IT WOULD START THEN DIE. THE FUEL PUMP HAD TO BE REPLACED. MY CAR HAS 85,000 MILES ON IT AND I BOUGHT IT WITH A SALVAGE TITLE IN JANUARY 2006. THE FUEL PUMP MY CAR HAS IT THE ORIGINAL MANUFACTURERS. *TR
NHTSA ODI #10274230
90,000 miles · Jun 14, 2009
Fuel System, Gasoline
I HAVE A 2003 CAVALIER AND I HAD TO REPLACE THE FUEL PUMP AT 90,000MILES AGAIN !!!THIS IS SHAMEFUL 4 CHEVY , I SAVED MY RECIPE BECAUSE IT COST ME 600 DOLLARS TO FIX IT,GOOD BYE SUMMER SCHOOL LOOKS LIKE MY GRADUATION IS GOING BE DELAYED HALF YEAR. *TR
NHTSA ODI #10273757
58,000 miles · Jun 9, 2009
Fuel System, Gasoline
2003 CAVALIER CUT OFF AND WOULD NOT RESTART. CAR HAS 58,000 MILES ON IT. FUEL PUMP HAD TO BE REPLACED. *TR
NHTSA ODI #10273175
39,000 miles · Jun 7, 2009
Electrical System
THE INSTRUMENT CLUSTER ON MY 2003 CHEVY CAVALIER WENT CRAZY JUST BEFORE 40, 000 MILES. SOMETIMES IT WORKS, SOMETIMES THE GAUGES TAKE TURNS WORKING OR NOT WORKING, SOMETIMES NOTHING WORKS. SOME DAYS I DON'T KNOW HOW FAST I'M GOING, HOW HOT MY CAR'S RUNNING, OR HOW MUCH GAS I HAVE....NOT TO MENTION RPMS. THIS IS VERY UNSAFE, AND A…
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THE INSTRUMENT CLUSTER ON MY 2003 CHEVY CAVALIER WENT CRAZY JUST BEFORE 40, 000 MILES. SOMETIMES IT WORKS, SOMETIMES THE GAUGES TAKE TURNS WORKING OR NOT WORKING, SOMETIMES NOTHING WORKS. SOME DAYS I DON'T KNOW HOW FAST I'M GOING, HOW HOT MY CAR'S RUNNING, OR HOW MUCH GAS I HAVE....NOT TO MENTION RPMS. THIS IS VERY UNSAFE, AND AT 40K, I FEEL IT'S A BIT PREMATURE. *TR
NHTSA ODI #10273037
10,480 miles · Jun 2, 2009
Fuel System, Gasoline
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING 40 MPH, THE VEHICLE BEGAN TO SLOW DOWN. IT THEN CAME TO A COMPLETE STOP BEFORE SHUTTING OFF. THE VEHICLE WAS RESTARTED, BUT WOULD NOT MOVE. THE VEHICLE WAS TOWED TO A REPAIR SHOP AND THE MECHANIC STATED THAT THE FUEL PUMP FAILED. THE DEALER WAS NOT NOTIFIED. THE …
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TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING 40 MPH, THE VEHICLE BEGAN TO SLOW DOWN. IT THEN CAME TO A COMPLETE STOP BEFORE SHUTTING OFF. THE VEHICLE WAS RESTARTED, BUT WOULD NOT MOVE. THE VEHICLE WAS TOWED TO A REPAIR SHOP AND THE MECHANIC STATED THAT THE FUEL PUMP FAILED. THE DEALER WAS NOT NOTIFIED. THE VEHICLE IS CURRENTLY STILL AT THE REPAIR SHOP AND WILL BE REPAIRED. THROUGH RESEARCH, THE CONTACT DISCOVERED THAT MANY CONSUMERS WERE EXPERIENCING THE SAME ISSUES WITH THEIR CAVALIERS. THE VIN WAS UNKNOWN. THE FAILURE AND CURRENT MILEAGES WERE 10,480.
NHTSA ODI #10272708
55,000 miles · May 27, 2009
Fuel System, Gasoline
SEVERAL TIMES MY VEHICLE HAS BEEN UNABLE TO START DUE TO THE FUEL PUMP. THE FUEL PUMP HAD TO BE REPLACED TWICE IN THE PAST 3 YEARS, AND AGAIN TODAY. IF THE VEHICLE HAS LESS THAN A 1/4 OF A TANK OF GAS AND IT IS PARKED ON AN INCLINE WITH THE FRONT OF THE VEHICLE ABOVE THE REAR, IT USUALLY WON'T START. WHEN I AM BELOW A QUARTER…
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SEVERAL TIMES MY VEHICLE HAS BEEN UNABLE TO START DUE TO THE FUEL PUMP. THE FUEL PUMP HAD TO BE REPLACED TWICE IN THE PAST 3 YEARS, AND AGAIN TODAY. IF THE VEHICLE HAS LESS THAN A 1/4 OF A TANK OF GAS AND IT IS PARKED ON AN INCLINE WITH THE FRONT OF THE VEHICLE ABOVE THE REAR, IT USUALLY WON'T START. WHEN I AM BELOW A QUARTER OF A TANK, I HAVE TO PARK IT WITH THE REAR ABOVE THE FRONT ON AN INCLINE. *TR
NHTSA ODI #10270031
66 miles · May 26, 2009
Fuel System, Gasoline
DRIVING ON HIGHWAY AND WENT TO ACCELERATE AND CAR JUST STOPPED. HAD TO HAVE IT TOWED TO DEALERSHIP AND TOLD FUEL PUMP NEEDED TO BE REPLACED. COST WAS $875. CAR HAS 66,000 MILES. *TR
NHTSA ODI #10269906
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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