NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
678 reports170,000 miles · Apr 6, 2014
Electrical System
ERRATIC INSTRUMENT PANEL..SOMETIMES AFTER TURNING IGNITION KEY ON ALL PANEL LIGHTS STAY ON (BEYOND NORMAL)AND ALL GAUGES GO OFF..SOMETIMES OK WHEN STARTING BUT SOME LIGHTS COME ON (AIR BAG, SERVICE ENG, ABS GAS GAUGE, ETC) AFTER DRIVING ..SOMETIMES ALL INSTR GAUGES GO OUT COMPLETELY WHILE DRIVING INCLUDING SPEEDOMETER...THEY SOM…
Read full complaint
ERRATIC INSTRUMENT PANEL..SOMETIMES AFTER TURNING IGNITION KEY ON ALL PANEL LIGHTS STAY ON (BEYOND NORMAL)AND ALL GAUGES GO OFF..SOMETIMES OK WHEN STARTING BUT SOME LIGHTS COME ON (AIR BAG, SERVICE ENG, ABS GAS GAUGE, ETC) AFTER DRIVING ..SOMETIMES ALL INSTR GAUGES GO OUT COMPLETELY WHILE DRIVING INCLUDING SPEEDOMETER...THEY SOMETIMES COME BACK ON AND SOMETIMES NOT...I ENTERED MY MAKE AND YEAR ON GOOGLE TO SEE IF OTHER OWNERS HAVE SIMILAR PROBLEM AND FOUND OUT MANY DO..INTERESTING TO NOTE THAT WHILE RESEARCHING ON GOOGLE I FOUND OUT CHEV TRUCKS IN YEAR 2003 HAD A RECALL DUE TO FAULTY INSTRUMENT PANEL CONTROLS BUT THE AUTOS WERE NOT RECALLED.. I FEEL THIS IS A DEFINITE SAFETY HAZARD SINCE I SOMETIMES HAVE TO DRIVE WITH NO SPEEDOMETER, GAS GAUGE AND AN AIRBAG LIGHT THAT STAYS ON. I DO NOT FEEL SAFE DRIVING THIS VEHICLE FOR ANY LENGTH OF TIME AND HAVE TO RESORT TO ONLY SHORT TRIPS (GROCERY STORE, DR APPTS, ETC) I WOULD LIKE TO KNOW WHY GM HAS NOT RECALLED THIS 2003 CHEVY CAVALIER..ESP WHEN THEY HAVE RECALLED THE SAME YR AND MAKE TRUCKS FOR FAULTY INSTR PANELS.. I FEEL THIS FAULTY INSTR PANEL IS PLACING ME IN A VERY DANGEROUS POSITION EACH TIME I GET BEHIND THE WHEEL AND NEEDLESS TO SAY DO NOT FEEL SAFE DRIVING THIS AUTO AT ALL... *TR
NHTSA ODI #10577775
109,801 miles · Mar 18, 2014
Structure
ON OR ABOUT MARCH 8TH, 2014, I NOTICED THAT HOLES HAD APPEARED ON THE DRIVERS AND PASSENGER SIDE OF THE VEHICLE ON THE BOTTOM AND WHEN I WENT TO FURTHER EXAM THE HOLE, I THEN REALIZED THE UNDERSIDE OF THE CAR IS COMPLETELY CORRODED. THE SHEET METAL ON THE PASSENGERS SIDE IS COMING OFF IN SHEETS AND THE HOLE HAS BECOME MUCH LAR…
Read full complaint
ON OR ABOUT MARCH 8TH, 2014, I NOTICED THAT HOLES HAD APPEARED ON THE DRIVERS AND PASSENGER SIDE OF THE VEHICLE ON THE BOTTOM AND WHEN I WENT TO FURTHER EXAM THE HOLE, I THEN REALIZED THE UNDERSIDE OF THE CAR IS COMPLETELY CORRODED. THE SHEET METAL ON THE PASSENGERS SIDE IS COMING OFF IN SHEETS AND THE HOLE HAS BECOME MUCH LARGER IN SIZE. ALSO, THE VEHICLE PULLS TO THE LEFT AND RIGHT PRETTY STRONGLY. THE INSIDE FLOOR OF THE CAR FEELS SQUISHY LIKE THE FLOOR IS GOING TO FALL OUT. HIGHER SPEEDS SEEM TO MAKE MORE SHEET METAL FALL OFF. *TR
NHTSA ODI #10573211
Mileage unknown · Mar 17, 2014
Electronic Stability Control (esc)
AFTER I DRIVE CAR FOR 5 THEN SYSTEM SECURITY LIGHT COMES, AND MANY OTHER LIGHTS COME ON DASH BOARD AND ALL THE GAUGES DROPPED TO ZERO. PEPBOYS SAYS IT IS BAD BCM. *TR
NHTSA ODI #10572820
88,000 miles · Mar 10, 2014
Power Train
WHEN SHIFTING AUTO TRANSMISSION INTO REVERSE GEAR FROM PARK THE CLIP THAT HOLDS THE SHIFT CABLE ONTO THE SHIFT LEVER ON THE TRANSMISSION BROKE. DEALER TOLD ME THAT ENTIRE SHIFT CABLE MUST BE PURCHASED TO GET THE SMALL CLIP THAT HOLDS CABLE END TO TRANSMISSION SHIFT LEVER. I WENT TO A LOCAL JUNK YARD TO FIND THIS SMALL CLIP (PA…
Read full complaint
WHEN SHIFTING AUTO TRANSMISSION INTO REVERSE GEAR FROM PARK THE CLIP THAT HOLDS THE SHIFT CABLE ONTO THE SHIFT LEVER ON THE TRANSMISSION BROKE. DEALER TOLD ME THAT ENTIRE SHIFT CABLE MUST BE PURCHASED TO GET THE SMALL CLIP THAT HOLDS CABLE END TO TRANSMISSION SHIFT LEVER. I WENT TO A LOCAL JUNK YARD TO FIND THIS SMALL CLIP (PART) AND WAS ASTONISHED TO FIND THAT EVERY AUTO OF THIS YEAR AND MAKE HAD THE SIMILAR PROBLEM. ALL OF THESE AUTOS HAS THE CABLE WIRED TO THE SHIFT LEVER. SOME USED A WIRE TIE TO SECURE THE LEVER TO CABLE. THE TOW TRUCK DRIVER WHO RESPONDED TO TOW MY VEHICLE SAID HE SEES THIS PROBLEM "ALL THE TIME". WHEN I CALLED THE LOCAL CHEVY DEALER THEY SAID THEY WERE OUT OF STOCK FOR THIS CABLE AND CLIP AND HAD TO ORDER IT. THIS MAY ALSO INDICATE THAT THIS PROBLEM IS WIDE SPREAD. IF THIS SHIFT CABLE WERE TO FALL OFF WHILE TRYING TO MANUALLY SHIFT THE AUTO TRANSMISSION, WELL, I AM SURE YOU UNDERSTAND THE RESULTS. *TR
NHTSA ODI #10568096
115,000 miles · Mar 5, 2014
Electrical System
THE ENTIRE INSTRUMENT CLUSTER PANEL COMPLETELY WENT HAY WIRE AND THE SPEED WOULD INCREASE AND DECREASE. EVERYTHING WAS FLASHING TO THE POINT IT WAS ACTUALLY SCARY. I PULLED OVER TO THE SIDE OF THE ROAD AND IT STILLED CONTINUED. I FINALLY DECIDED TO CONTINUE HOME AND AFTER ABOUT 6 MILES IT FINALLY JUST STOPPED. I RESEARCHED T…
Read full complaint
THE ENTIRE INSTRUMENT CLUSTER PANEL COMPLETELY WENT HAY WIRE AND THE SPEED WOULD INCREASE AND DECREASE. EVERYTHING WAS FLASHING TO THE POINT IT WAS ACTUALLY SCARY. I PULLED OVER TO THE SIDE OF THE ROAD AND IT STILLED CONTINUED. I FINALLY DECIDED TO CONTINUE HOME AND AFTER ABOUT 6 MILES IT FINALLY JUST STOPPED. I RESEARCHED THIS PROBLEM ON THE INTERNET AND HAVE FOUND THAT SO MANY MORE HAVE EXPERIENCED THE SAME THING HAPPENING BUT SOME HAVE HAD THEIR CAR ACTUALLY START ON FIRE. PLEASE ADVISE IF THERE IS ANY RECALL IN THE NEAR FUTURE BEFORE SOMEONE HAS TO LOSE THEIR LIFE OVER THIS. THANK YOU SO MUCH FOR ANY CONSIDERATION. *TR
NHTSA ODI #10567491
123,100 miles · Dec 13, 2013
Engine And Engine CoolingFuel System, Gasoline
WAS IN THE FAST LANE AND CAR SHUT OFF AND TRIED TO RESTART BUT IT WOULD NOT. WAS STUCK IN THE ROAD CARS HONKING CAR WOULD NOT RESTART. *TR
NHTSA ODI #10555936
90,000 miles · Jun 11, 2013
Structure
TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT WHILE AT AN INDEPENDENT MECHANIC FOR THE REPLACEMENT OF CORRODED BRAKE LINES, THE MECHANIC NOTICED THAT THE FRAME WAS ALSO CORRODED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS NOT AVAILABLE. THE APPROXIMATE …
Read full complaint
TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT WHILE AT AN INDEPENDENT MECHANIC FOR THE REPLACEMENT OF CORRODED BRAKE LINES, THE MECHANIC NOTICED THAT THE FRAME WAS ALSO CORRODED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS NOT AVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 90,000. *TR
NHTSA ODI #10516215
140,000 miles · Jun 9, 2013
Fuel System, Gasoline
COASTING DOWN HILL ON A DIRT ROAD, GOT TO THE BOTTOM AND ENGINE HAD DIED. ROLLED TO A STOP AND WOULD NOT RESTART. TOWED TO A MECHANIC, REPLACED FUEL PUMP. THIS HAPPENED TWICE MORE AND EACH TIME THE FUEL PUMP WAS BAD. THE LAST FUEL PUMP ONLY LASTED 3 MONTHS AND LIKE THE TWO PREVIOUS PUMPS, IT WAS BRAND NEW!! THIS IS 3 BAD FU…
Read full complaint
COASTING DOWN HILL ON A DIRT ROAD, GOT TO THE BOTTOM AND ENGINE HAD DIED. ROLLED TO A STOP AND WOULD NOT RESTART. TOWED TO A MECHANIC, REPLACED FUEL PUMP. THIS HAPPENED TWICE MORE AND EACH TIME THE FUEL PUMP WAS BAD. THE LAST FUEL PUMP ONLY LASTED 3 MONTHS AND LIKE THE TWO PREVIOUS PUMPS, IT WAS BRAND NEW!! THIS IS 3 BAD FUEL PUMPS IN A YEAR AND MY WALLET CAN'T AFFORD TO KEEP THIS UP. WHY IS THERE NOT A RECALL ON THIS? *TR
NHTSA ODI #10515919
76,000 miles · May 26, 2013
Steering
DRIVING AT LOW SPEED. STEERING WHEEL EXPERIENCED EXCESSIVE SIDE PLAY. MADE APPOINTMENT AT LOCAL MECHANIC (NON-DEALER) STEERING HOUSING TAKEN OFF AND FOUND ONE OF TWO PINS IN THE STEERING COLUMN FOR THE TILT MECHANISM HALF WAY OUT OF HOUSING. MECHANIC REINSERTED PIN AND ATTEMPTED TO RESTAKE PIN IN HOUSING. EXPERIENCED NO SIDE P…
Read full complaint
DRIVING AT LOW SPEED. STEERING WHEEL EXPERIENCED EXCESSIVE SIDE PLAY. MADE APPOINTMENT AT LOCAL MECHANIC (NON-DEALER) STEERING HOUSING TAKEN OFF AND FOUND ONE OF TWO PINS IN THE STEERING COLUMN FOR THE TILT MECHANISM HALF WAY OUT OF HOUSING. MECHANIC REINSERTED PIN AND ATTEMPTED TO RESTAKE PIN IN HOUSING. EXPERIENCED NO SIDE PLAY AFTER REPAIR FOR ABOUT 1 WEEK AND PROBLEM HAS RESURFACED. *TR
NHTSA ODI #10513599
65,045 miles · May 21, 2013
Fuel/propulsion System
MY BOYFRIEND WAS DRIVING OUR CAR. I WAS IN THE PASSENGER SEAT. WE HAD BEEN DRIVING ON THE INTERSTATE FOR ABOUT A MILE. THEN THE CAR STALLED. MY FRIEND REALIZED SOMETHING WAS WRONG WHEN HE HIT THE GAS PEDAL AND THERE WAS NO RESPONSE, SO HE PLACED IT IN NEUTRAL, STEERED AND SIGNALED UNTIL HE GOT US AND THE CAR SAFELY OFF THE ROA…
Read full complaint
MY BOYFRIEND WAS DRIVING OUR CAR. I WAS IN THE PASSENGER SEAT. WE HAD BEEN DRIVING ON THE INTERSTATE FOR ABOUT A MILE. THEN THE CAR STALLED. MY FRIEND REALIZED SOMETHING WAS WRONG WHEN HE HIT THE GAS PEDAL AND THERE WAS NO RESPONSE, SO HE PLACED IT IN NEUTRAL, STEERED AND SIGNALED UNTIL HE GOT US AND THE CAR SAFELY OFF THE ROAD. AFTER, THE CAR WAS TOWED INTO THE DEALERS SHOP THE MECHANICS SAID IT WAS THE FUEL PUMP THAT HAD FAILED TO WORK. THEREFORE, A NEW FUEL PUMP WAS INSTALLED IN THE CAR. *TR
NHTSA ODI #10513050
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.
Illustration