IllustrationPOWER 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
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
What owners actually said
678 reportsI 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
INSTRUMENT CLUSTER GAUGES MALFUNCTION PERIODICALLY AND LOCK INTO ONE POSITION OR DON'T WORK AT ALL. CANT TELL WHAT YOUR SPEED IS , TEMP IS, RPM ETC! THIS I THINK IS A SAFETY ISSUE AND SHOULD BE ADDRESSED. I SEE THIS IS HAPPENING TO MANY PEOPLE AS I HAVE INVESTIGATED IT ON LINE. THIS IS PRETTY MUCH WHAT'S HAPPENING... HTTPS://W…
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INSTRUMENT CLUSTER GAUGES MALFUNCTION PERIODICALLY AND LOCK INTO ONE POSITION OR DON'T WORK AT ALL. CANT TELL WHAT YOUR SPEED IS , TEMP IS, RPM ETC! THIS I THINK IS A SAFETY ISSUE AND SHOULD BE ADDRESSED. I SEE THIS IS HAPPENING TO MANY PEOPLE AS I HAVE INVESTIGATED IT ON LINE. THIS IS PRETTY MUCH WHAT'S HAPPENING... HTTPS://WWW.YOUTUBE.COM/WATCH?V=RZILY3GXEXA. *TR
TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT WHILE DRIVING 35 MPH, THE VEHICLE STALLED. THE VEHICLE COULD BE RESTARTED AND THE VEHICLE FUNCTION NORMALLY. THE FAILURE OCCURRED ON NUMEROUS OCCASIONS. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILUR…
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TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT WHILE DRIVING 35 MPH, THE VEHICLE STALLED. THE VEHICLE COULD BE RESTARTED AND THE VEHICLE FUNCTION NORMALLY. THE FAILURE OCCURRED ON NUMEROUS OCCASIONS. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 26,914 AND THE CURRENT MILEAGE WAS 27,914.
TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT WHILE DRIVING AT UNKNOWN SPEEDS, THE VEHICLE STALLED. THE CONTACT MENTIONED THAT WHEN ATTEMPTING TO RESTART THE VEHICLE, IT MADE A LOUD POPPING NOISE. THE VEHICLE WAS NOT TAKEN TO A DEALER. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF…
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TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT WHILE DRIVING AT UNKNOWN SPEEDS, THE VEHICLE STALLED. THE CONTACT MENTIONED THAT WHEN ATTEMPTING TO RESTART THE VEHICLE, IT MADE A LOUD POPPING NOISE. THE VEHICLE WAS NOT TAKEN TO A DEALER. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 40,000 AND THE CURRENT MILEAGE WAS 41,000.
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
TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT THE KEY SEIZED IN THE IGNITION AND THEY WERE UNABLE TO SHUT THE ENGINE DOWN. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 50,000 AND THE CURRENT MILEAGE WAS 130,000. UPDATED 08/19/14*LJ U…
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TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT THE KEY SEIZED IN THE IGNITION AND THEY WERE UNABLE TO SHUT THE ENGINE DOWN. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 50,000 AND THE CURRENT MILEAGE WAS 130,000. UPDATED 08/19/14*LJ UPDATED 08/23/2017*CT
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
WENT TO START CAR TO GO TO STORE AND IT WOULD NOT START. LUCKILY IT WAS AT HOME WHEN IT DECIDED TO STOP WORKING. TOWED TO GARAGE AND THEY SAID IT WAS THE FUEL PUMP. THE GARAGE REPLACED THE FUEL PUMP AND IT FIXED THE NO START ISSUE. I HAD NO IDEA THAT THIS WAS THE PROCESS TO START A RECALL INVESTIGATION OR I WOULD HAVE …
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WENT TO START CAR TO GO TO STORE AND IT WOULD NOT START. LUCKILY IT WAS AT HOME WHEN IT DECIDED TO STOP WORKING. TOWED TO GARAGE AND THEY SAID IT WAS THE FUEL PUMP. THE GARAGE REPLACED THE FUEL PUMP AND IT FIXED THE NO START ISSUE. I HAD NO IDEA THAT THIS WAS THE PROCESS TO START A RECALL INVESTIGATION OR I WOULD HAVE SAID LONG AGO. THERE HAS BEEN LOTS OF RECALLS LATELY ON GM AND THIS SAME CAVALIER DECIDED NOT TO START TWICE AFTER THE FUEL PUMP, ONCE IN 2011 WAS THE TIMING CHAIN THEN AGAIN DECEMBER 2012 THAT I STILL HAVE TO DIAGNOSE WHICH LED ME TO RESEARCH RECALLS. EACH TIME THE CAR STOPPED WORKING LUCKILY IT WAS IN MY DRIVEWAY EACH AND EVERY TIME. THE TIMING CHAIN THERE WAS SOME WARNING, IT WOULD SOMETIMES BUCK, OTHER TIMES IT WAS FUSSY ON STARTING AND IT WOULD STALL AT STOP LIGHTS. I WILL REPORT A NEW ISSUE IF I CAN FIND OUT THE 3RD UNKNOWN 2012 ISSUE. *TR
CLUSTER DEFECT: PURCHASED A 2003 CHEVY CAVALIER BRAND NEW OFF THE LOT IN DECEMBER OF 2002. JUST AFTER 5 YEARS AND APPROXIMATELY 55,000 MILES, WE ARE DRIVING DOWN THE HIGHWAY DURING SNOWFALL WHILE THE SPEEDOMETER STATED WE WERE TRAVELING AT 65 MILES PER HOUR, WE DID NOT KNOW THAT THE SPEEDOMETER WAS NOT READING CORRECTLY UNTIL WE…
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CLUSTER DEFECT: PURCHASED A 2003 CHEVY CAVALIER BRAND NEW OFF THE LOT IN DECEMBER OF 2002. JUST AFTER 5 YEARS AND APPROXIMATELY 55,000 MILES, WE ARE DRIVING DOWN THE HIGHWAY DURING SNOWFALL WHILE THE SPEEDOMETER STATED WE WERE TRAVELING AT 65 MILES PER HOUR, WE DID NOT KNOW THAT THE SPEEDOMETER WAS NOT READING CORRECTLY UNTIL WE GOT TO A CORNER AND THE SPEEDOMETER SHOWED WE WERE DRIVING AT ABOUT 20 MPH WHEN WE WERE FLYING AT ATLEAST 50 MPH WHICH INDICATED THE SPEEDOMETER WAS ABOUT 30 MPH OFF. THEN THE TACHOMETER WOULD STOP WORKING, GET STUCK, OR NOT OPERATE CORRECTLY. I THEN BEGAN TO HAVE PROBLEMS WITH ALL OF THE GAUGES, THE GAS GAUGE NEEDLE WOULD GO BACKWARDS ON TOP OF THE TEMPERATURE GAUGE CAUSING THE TEMPERATURE GAUGE TO STOP WORKING THEN ALL GAUGES WOULD MALFUNCTION, THEN THEY WOULD STOP WORKING COMPLETELY. I TOOK IT INTO THE CHEVY DEALERSHIP, THEY CAME BACK TO ME AND SAID IT'S WORKING FINE, THERE'S NOTHING WRONG WITH IT. AND AGAIN AND AGAIN AND AGAIN THE GAUGES CONTINUE TO GO HAYWIRE CHEVY STATED WHEN I TOOK THE VEHICLE IN THAT THEY HAVE NEVER HEARD OF SUCH A COMPLAINT AND I TOLD THEM TO LOOK IT UP ON THE INTERNET, THERE ARE HUNDREDS/THOUSANDS OF COMPLAINTS REGARDING THIS PROBLEM. CURRENTLY NONE OF MY GAUGES ARE WORKING AND AM HAVING TO USE A GPS TO NAVIGATE SPEED AND FILL MY VEHICLE UP EVERY 4 DAYS BECAUSE I HAVE NO IDEA WHEN THE CAR IS ON EMPTY. IT IS HIGH TIME SOMETHING BE DONE ABOUT THIS. CHEVY RECALLED A BUNCH OF OTHER MODELS, BUT NOT THE CARS. SOMETHING HAS TO BE DONE ABOUT THIS AND QUICKLY BEFORE SOMEONE IS KILLED. OR DOES IT TAKE A DEATH OR MANY MORE TO GET SOMEONE'S ATTENTION THAT THIS PROBLEM NEEDS TO BE ADDRESSED. PLEASE INVESTIGATE THIS DEFECT FURTHER. THERE ARE TOO MANY OF US OUT THERE THAT ARE DEALING WITH THIS PROBLEM AND ARE JUST KEEPING QUIET ABOUT IT. THIS PROBLEM DEFINITELY WARRANTS A RECALL AND FAST. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *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.