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
What owners actually said
678 reports
200,000 miles · Feb 9, 2016
StructureSuspension
I HAVE NOTICED A LOT AND I MEAN A LOT OF THESE CAVALIERS HAVE HAD HORRIBLE FRAME PROBLEMS I USE TO WORK ON CARS EVERYDAY UNTIL THE LAST YEAR WHEN I GOT OUT OF THE MECHANICS FIELD AN NOW I OWN A 03 CHEVY CAVALIER ITS A TWO DOOR 5 SPEED 2.2 I WAS ON MY WAY HOME FROM THE STORE AND I FELT SOMETHING RUBBING SO I STOPPED AN GOT OUT TO…
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I HAVE NOTICED A LOT AND I MEAN A LOT OF THESE CAVALIERS HAVE HAD HORRIBLE FRAME PROBLEMS I USE TO WORK ON CARS EVERYDAY UNTIL THE LAST YEAR WHEN I GOT OUT OF THE MECHANICS FIELD AN NOW I OWN A 03 CHEVY CAVALIER ITS A TWO DOOR 5 SPEED 2.2 I WAS ON MY WAY HOME FROM THE STORE AND I FELT SOMETHING RUBBING SO I STOPPED AN GOT OUT TO FIND OUT MY K FRAME WAS HORRIBLY ROTTED AN BROKE NOW THIS VEHICLE IS 13 YEARS OLD BUT AS ROTTED OUT AS IT WAS IT WASN'T SOMETHING THAT JUST HAPPENED ITS BEEN BAD I WAS JUST THE LUCKY OWNER THAT THE FRAME GAVE OUT ON AN I DEMAND TO KNOW WHY THIS ISN'T A RECALL ANOTHER THING IS I OWNED A 98 FORD F150 WHICH HAD RECALLS AN WHEN I WAS SENT THE LETTER ABOUT THE RECALLS I ASKED FORD WHY THE FRAMES ON THE F150 OR RANGER WASN'T A RECALL THEY HAD NO ANSWER. I PUT MY CHILD IN THESE AUTO MAKERS CARS AND TRUST THEIR WORK TO KEEP HIM SAFE BUT THEY HAVE NO ANSWER FOR WHY ONE OF THE MOST IMPORTANT PART ON THE WHOLE VEHICLE IS FALLING APART. I DON'T KNOW IF THEY NEED TO USE STAINLESS STEEL, ALUMINUM, OR WHAT BUT IT NEEDS FIXED OR THE VEHICLES NEED REIMBURSED AN CRUSHED. I COULD OF BEEN DOING 70 MPH DOWN THE HIGHWAY WITH MY WOMAN AN SON IN THE CAR AN THE FRAME COULD OF WENT AND KILLED US ALL. IS THAT WHAT ITS GONNA TAKE TO GET THIS [XXX] FIXED SOMEONE ELSE TO DIE/HURT. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
NHTSA ODI #10825225
Mileage unknown · Jan 20, 2016
Unknown Or Other
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.
NHTSA ODI #10821266
Mileage unknown · Dec 14, 2015
Service BrakesSteeringSuspension
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.
NHTSA ODI #10810161
Mileage unknown · Nov 2, 2015
Air BagsExterior LightingCrashInjury
TL* THE CONTACT OWNED A 2003 CHEVROLET CAVALIER. WHILE DRIVING 5 MPH ENTERING THE HIGHWAY, THE TURN SIGNAL LAMPS FAILED TO ILLUMINATE WHEN ACTIVATED AND RESULTED IN A CRASH. THE CONTACT'S VEHICLE WAS STRUCK ON THE REAR DRIVER SIDE AND SPUN ONTO THE ROADSIDE. THE AIR BAGS DID NOT DEPLOY AND A POLICE REPORT WAS FILED. ALL THREE OC…
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TL* THE CONTACT OWNED A 2003 CHEVROLET CAVALIER. WHILE DRIVING 5 MPH ENTERING THE HIGHWAY, THE TURN SIGNAL LAMPS FAILED TO ILLUMINATE WHEN ACTIVATED AND RESULTED IN A CRASH. THE CONTACT'S VEHICLE WAS STRUCK ON THE REAR DRIVER SIDE AND SPUN ONTO THE ROADSIDE. THE AIR BAGS DID NOT DEPLOY AND A POLICE REPORT WAS FILED. ALL THREE OCCUPANTS IN THE VEHICLE WERE SEVERELY INJURED AND REQUIRED MEDICAL ATTENTION. THE VEHICLE WAS DESTROYED. THE VIN WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 04V524000 (EXTERIOR LIGHTING). THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS UNKNOWN. ...UPDATED 02/19/16 *BF UPDATED 09/20/16*LJ *TR
NHTSA ODI #10787770
Mileage unknown · Oct 28, 2015
Electronic Stability Control (esc)
TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT THE IGNITION SWITCH FAILED. THE CONTACT WAS UNABLE TO TURN THE KEY TO THE ON FUNCTION AND HAD TO WIGGLE THE KEY TO BE ABLE TO RELEASE THE KEY FROM THE IGNITION. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAIL…
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TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT THE IGNITION SWITCH FAILED. THE CONTACT WAS UNABLE TO TURN THE KEY TO THE ON FUNCTION AND HAD TO WIGGLE THE KEY TO BE ABLE TO RELEASE THE KEY FROM THE IGNITION. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS NOT AVAILABLE. THE VIN WAS NOT AVAILABLE.
NHTSA ODI #10786735
Mileage unknown · Oct 21, 2015
Exterior Lighting
TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING 40 MPH, THE LEFT AND RIGHT TURN SIGNALS BECAME INOPERABLE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE VIN WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 04V524000 (EXTERIOR LIGHTING). THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS UNKNOWN.
NHTSA ODI #10784949
Mileage unknown · Oct 1, 2015
Electrical System
JULY 2009 IGNITION LOCK CYLINDER WAS STUCK. I HAD IT REPLACED FOR $362.75 AT CHEVROLET DEALERSHIP. AUGUST 2014 IGNITION LOCK CYLINDER WAS STUCK. I HAD IT REPLACED FOR $488.83 AT CHEVROLET DEALERSHIP. SEPTEMBER 2015 IGNITION LOCK CYLINDER WAS STUCK, MY KEY CAME OUT OF LOCK AND THE CAR WAS STILL RUNNING. I HAD TO COME OFF O…
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JULY 2009 IGNITION LOCK CYLINDER WAS STUCK. I HAD IT REPLACED FOR $362.75 AT CHEVROLET DEALERSHIP. AUGUST 2014 IGNITION LOCK CYLINDER WAS STUCK. I HAD IT REPLACED FOR $488.83 AT CHEVROLET DEALERSHIP. SEPTEMBER 2015 IGNITION LOCK CYLINDER WAS STUCK, MY KEY CAME OUT OF LOCK AND THE CAR WAS STILL RUNNING. I HAD TO COME OFF OF THE CLUTCH TO PURPOSELY MAKE THE CAR CUT OFF AND HAD TO UNPLUG THE BATTERY. THE 2003 CHEVROLET IS NOT INCLUDED IN THE RECALL BUT IT NEEDS TO BE. MY IGNITION LOCK CYLINDER HAS FAILED ME 3 TIMES IN THE PAST 6 YEARS. THANKFULLY, I'M ALIVE AND ABLE TO TELL YOU ALL ABOUT THIS. CHEVROLET & GM KNEW ABOUT THE LOCK CYLINDER RECALL WHEN I HAD MINE REPLACED LAST YEAR.
NHTSA ODI #10779168
Mileage unknown · Sep 9, 2015
StructureUnknown Or Other
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.
NHTSA ODI #10762383
184,000 miles · Apr 7, 2015
Steering
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
NHTSA ODI #10704146
8,161 miles · Mar 25, 2015
Electrical SystemPower Train
TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT THE VEHICLE COULD NOT BE SHIFTED OUT OF PARK. WHEN THE CONTACT INSERTED THE KEY INTO THE IGNITION SWITCH, IT BECAME DIFFICULT TO TURN AND THE OVERHEAD LIGHT DID NOT TURN OFF. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAI…
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TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT THE VEHICLE COULD NOT BE SHIFTED OUT OF PARK. WHEN THE CONTACT INSERTED THE KEY INTO THE IGNITION SWITCH, IT BECAME DIFFICULT TO TURN AND THE OVERHEAD LIGHT DID NOT TURN OFF. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 8,161.
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 ↗
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.
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.
2003 Chevrolet Cavalier Problems, Complaints & Recalls | Skip That Year
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