NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
678 reports31,199 miles · Jul 27, 2007
Fuel System, Gasoline
MY 2003 CHEVY CAVALIER HAS STALLED OUT SEVERAL TIMES WHILE I WAS DRIVING DOWN THE ROAD AT SPEEDS NOT OVER 25 MPH. THIS WAS VERY SCARY AND IT DEFINITELY COULD HAVE CAUSED A BIG PROBLEM AT A HIGHER RATE OF SPEED, BECAUSE YOU LOSE EVERYTHING WHEN IT DIES. I JUST HAD TO REPLACE THE FUEL PUMP , ON A CAR THAT IS LESS THAN 4 YEARS OLD,…
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MY 2003 CHEVY CAVALIER HAS STALLED OUT SEVERAL TIMES WHILE I WAS DRIVING DOWN THE ROAD AT SPEEDS NOT OVER 25 MPH. THIS WAS VERY SCARY AND IT DEFINITELY COULD HAVE CAUSED A BIG PROBLEM AT A HIGHER RATE OF SPEED, BECAUSE YOU LOSE EVERYTHING WHEN IT DIES. I JUST HAD TO REPLACE THE FUEL PUMP , ON A CAR THAT IS LESS THAN 4 YEARS OLD, HAS LESS THAN 32,000 MILES ON IT, AND ALL MAINTENANCE HAS BEEN COMPLETED PER DEALER RECOMMENDATIONS. THE CARS WARRANTY WAS THE 3 YEAR/ 30,000 MILE WARRANTY, SO THE DEALERSHIP WOULD NOT HAVE HELPED WITH THE REPAIR BILL. THERE IS SOMETHING NOT QUITE RIGHT ABOUT THIS CAR EVEN THOUGH THE FUEL PUMP HAS BEEN REPLACED, AT TIMES IT GOES BY ITSELF WITHOUT MY FOOT ON THE GAS PEDAL- I HAVE TO APPLY THE BRAKE TO SLOW IT DOWN. *JB
NHTSA ODI #10197696
90,600 miles · Jul 27, 2007
Fuel System, Gasoline
MY 2003 CHEVY CAVALIER STALLED OUT WHILE GOING 35 MILES AN HOUR. THE CAR WAS TOWED TO AN AUTO SHOP WHERE THEY INFORMED ME MY FUEL PUMP FAILED. I DID RESEARCH ONLINE AND FOUND THIS FORUM INCLUDING 120 SIMILAR EXPERIENCES: HTTP://WWW.TOPIX.NET/FORUM/AUTOS/CHEVROLET-CAVALIER/TVINIC5TFU5SFSI5H THE FUEL PUMP WAS REPLACED FOR…
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MY 2003 CHEVY CAVALIER STALLED OUT WHILE GOING 35 MILES AN HOUR. THE CAR WAS TOWED TO AN AUTO SHOP WHERE THEY INFORMED ME MY FUEL PUMP FAILED. I DID RESEARCH ONLINE AND FOUND THIS FORUM INCLUDING 120 SIMILAR EXPERIENCES: HTTP://WWW.TOPIX.NET/FORUM/AUTOS/CHEVROLET-CAVALIER/TVINIC5TFU5SFSI5H THE FUEL PUMP WAS REPLACED FOR APPROXIMATELY $650 DOLLARS, WHICH INCLUDES TOWING, LABOR AND PARTS. *JB
NHTSA ODI #10197695
57,402 miles · Jul 23, 2007
Fuel System, Gasoline
SITTING IN DRIVE-THRU AND MOTOR QUIT. HAD TO PUSH CAR TO PARKING SPOT. TOWED TO DEALER AND THEY FOUND NO FUEL PRESSURE FROM FUEL PUMP. REPLACED FUEL PUMP ASSY. *TR
NHTSA ODI #10197200
55,000 miles · Jul 19, 2007
Fuel System, Gasoline
MY 2003 CHEVY CAVALIER WITH 55,000 MILES WAS RUNNING FINE, THEN ONE DAY AFTER DOING SOME GROCERY SHOPPING, I STARTED THE CAR AND IT STALLED. TRYING TO PULL OUT OF A PARKING SPACE IN THE SHOPPING CENTER, THE CAR STALLED AT LEAST 6 MORE TIMES. THE CHECK ENGINE LIGHT CAME ON AT START UP AND STAYED ON. I DROVE THE CAR AROUND THE …
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MY 2003 CHEVY CAVALIER WITH 55,000 MILES WAS RUNNING FINE, THEN ONE DAY AFTER DOING SOME GROCERY SHOPPING, I STARTED THE CAR AND IT STALLED. TRYING TO PULL OUT OF A PARKING SPACE IN THE SHOPPING CENTER, THE CAR STALLED AT LEAST 6 MORE TIMES. THE CHECK ENGINE LIGHT CAME ON AT START UP AND STAYED ON. I DROVE THE CAR AROUND THE PARKING LOT OF THE SHOPPING CENTER AND IT STARTED TO SETTLE DOWN. I DECIDED TO TRY AND DRIVE IT HOME WHERE THERE IS AN AUTO SHOP I USE RIGHT BY MY HOUSE. THE CAR DIDN'T MAKE IT EVEN A 1/2 MILE (ONLY TO THE NEXT TRAFFIC LIGHT) WHERE IT STALLED AT THE RED LIGHT LEAVING ME STRANDED IN THE MIDDLE OF A BUY INTERSECTION. I HAD SOME GUYS FROM A LOCAL GOODYEAR SHOP HELP ME PUSH THE VEHICLE INTO THEIR PARKING LOT, FROM WHICH I HAD THE CAR TOWED TO MY LOCAL SHOP. ON INVESTIGATION THE CAR NEEDED A NEW FUEL PUMP, WHICH A GM AUTHORIZED DEALER WOULD SELL FOR $700. *TR
NHTSA ODI #10196811
67,000 miles · Jul 18, 2007
Fuel System, Gasoline
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING 35 MPH, THE VEHICLE STALLED AND FAILED TO RESTART. THE CONTACT STRUCK THE GAS TANK WITH A HAMMER AND THE VEHICLE RESTARTED TEMPORARILY. CURRENTLY, THE VEHICLE WILL NO LONGER START. THERE IS AN ONGOING INVESTIGATION (# PE 07033) REGARDING THE FUEL PUMP. THE CURRENT…
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TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING 35 MPH, THE VEHICLE STALLED AND FAILED TO RESTART. THE CONTACT STRUCK THE GAS TANK WITH A HAMMER AND THE VEHICLE RESTARTED TEMPORARILY. CURRENTLY, THE VEHICLE WILL NO LONGER START. THERE IS AN ONGOING INVESTIGATION (# PE 07033) REGARDING THE FUEL PUMP. THE CURRENT AND FAILURE MILEAGES WERE 67,000.
NHTSA ODI #10196703
56,000 miles · Jul 16, 2007
Fuel System, Gasoline
WHILE DRIVING MY CAR STALLED. I WAS ABLE TO START IT AGAIN, BUT AGAIN IT STALLED, AND AFTERWARD IT WOULD NOT START. I HAD MY MECHANIC HELP ME MOVE THE CAR TO HIS SHOP, WHERE UPON FURTHER EXAMINATION HE DETERMINED THAT MY CAVALIER'S FUEL PUMP HAD FAILED WHILE THE CAR WAS IN MOTION. THE FUEL PUMP FAILED AT ONLY 56K MILES! THIS…
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WHILE DRIVING MY CAR STALLED. I WAS ABLE TO START IT AGAIN, BUT AGAIN IT STALLED, AND AFTERWARD IT WOULD NOT START. I HAD MY MECHANIC HELP ME MOVE THE CAR TO HIS SHOP, WHERE UPON FURTHER EXAMINATION HE DETERMINED THAT MY CAVALIER'S FUEL PUMP HAD FAILED WHILE THE CAR WAS IN MOTION. THE FUEL PUMP FAILED AT ONLY 56K MILES! THIS IS UNACCEPTABLE, IF I WERE ON A MAJOR HIGHWAY WHEN THE VEHICLE STALLED PEOPLE COULD HAVE DIED! *TR
NHTSA ODI #10196414
65,170 miles · Jul 9, 2007
Fuel System, Gasoline
FUEL PUMP DIED AT 65000 MILES... 35,000 MILES BEFORE FIRST TUNE-UP IWA SSCHEDULED. *AK
NHTSA ODI #10195621
92,083 miles · Jul 8, 2007
Fuel System, Gasoline
2003 CAVALIER'S FUEL PUMP FAILED AT 15 MPH. *AK
NHTSA ODI #10195583
65,000 miles · Jul 7, 2007
Fuel System, Gasoline
HAD TO REPLACE FUEL PUMP ON A 2003 CHEVROLET CAVALIER AT 65,000 MILES. THIS OCCURED ON 01/15/07. I WAS NEEDING TO LEAVE MY RESIDENCE AND THE CAVALIER WOULD NOT START. I HAD THE CAR TOWED TO MOLLE CHEVROLET,411 MOCKAVE. BLUE SPRINGS,MO. THEY MADE THE DETERMINATION OF THE FUEL PUMP FAILURE AND REPLACED THE PART AS WELL AS THE FUE…
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HAD TO REPLACE FUEL PUMP ON A 2003 CHEVROLET CAVALIER AT 65,000 MILES. THIS OCCURED ON 01/15/07. I WAS NEEDING TO LEAVE MY RESIDENCE AND THE CAVALIER WOULD NOT START. I HAD THE CAR TOWED TO MOLLE CHEVROLET,411 MOCKAVE. BLUE SPRINGS,MO. THEY MADE THE DETERMINATION OF THE FUEL PUMP FAILURE AND REPLACED THE PART AS WELL AS THE FUEL FILTER. *AK
NHTSA ODI #10195538
60,000 miles · Jul 5, 2007
Fuel System, Gasoline
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING 70 MPH, THE VEHICLE SHUT OFF AND FAILED TO ACCELERATE. THE MECHANIC STATED THAT THE CAUSE OF FAILURE WAS THE FUEL PUMP AND THEN MADE THE REPLACEMENT. APPROXIMATELY TWO MONTHS LATER, WHILE DRIVING 30 MPH, THE FAILURE RECURRED. AS OF JULY 5, 2007, THE VEHICLE HAS NOT…
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TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING 70 MPH, THE VEHICLE SHUT OFF AND FAILED TO ACCELERATE. THE MECHANIC STATED THAT THE CAUSE OF FAILURE WAS THE FUEL PUMP AND THEN MADE THE REPLACEMENT. APPROXIMATELY TWO MONTHS LATER, WHILE DRIVING 30 MPH, THE FAILURE RECURRED. AS OF JULY 5, 2007, THE VEHICLE HAS NOT BEEN REPAIRED. THE CURRENT MILEAGE IS 62,000 AND FAILURE MILEAGE WAS 60,000.
NHTSA ODI #10195416
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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