NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
678 reports34,000 miles · Feb 25, 2005
Electrical System
STARTING IN OCTOBER 2004, THE DASHBOARD LIGHTS IN MY 2003 CHEVROLET CAVALIER BEGAN TURNING OFF ANYTIME I DROVE THE VEHICLE WITH THE HEADLIGHTS TURNED ON. I TOOK THE CAR INTO A CHEVROLET DEALERSHIP FOUR TIMES REGARDING THIS PROBLEM AND IT HAS NEVER BEEN RESOLVED. THE FIRST TIME I TOOK THE CAR IN, THE DEALERSHIP INFORMED ME THAT…
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STARTING IN OCTOBER 2004, THE DASHBOARD LIGHTS IN MY 2003 CHEVROLET CAVALIER BEGAN TURNING OFF ANYTIME I DROVE THE VEHICLE WITH THE HEADLIGHTS TURNED ON. I TOOK THE CAR INTO A CHEVROLET DEALERSHIP FOUR TIMES REGARDING THIS PROBLEM AND IT HAS NEVER BEEN RESOLVED. THE FIRST TIME I TOOK THE CAR IN, THE DEALERSHIP INFORMED ME THAT THEY COULD NOT REPLICATE THE PROBLEM AND WERE UNABLE TO CONDUCT ANY REPAIRS. THE SECOND TIME, THE DEALERSHIP STILL COULD NOT REPLICATE THE PROBLEM, BUT REPLACED THE MULTI-FUNCTION SWITCH. THE THIRD TIME, I TOOK IT TO A DIFFERENT DEALERSHIP AND THEY MADE A "HIGHLY EDUCATED GUESS REPAIR." THE FOURTH AND LAST TIME, THE DEALERSHIP MADE NO REPAIR ATTEMPT AND BASICALLY TOLD ME TO NOT BRING THE VEHICLE IN AGAIN UNLESS I AM ABLE TO BRING IT IN WITH THE DASHBOARD LIGHTS TURNED OFF. AT THIS POINT, I AM DRIVING THE VEHICLE WITH A FLASHLIGHT IN THE CAR SO THAT I CAN SEE MY SPEED AND OTHER GAUGES WHEN THE DASHBOARD LIGHTS ARE OFF. WHILE THEY DO NOT TURN OFF EVERY TIME I DRIVE WITH THE HEADLIGHTS ON, THEY ARE OFF QUITE FREQUENTLY. AT THE WORST, I FEAR THIS WILL CAUSE AN ACCIDENT. AT THE LEAST, I ASSUME I WILL BE PULLED OVER AT SOME POINT FOR DRIVING WITH A FLASHLIGHT ON IN THE CAR. WHILE I UNDERSTAND THAT THE DEALERSHIP HAS NOT BEEN ABLE TO REPLICATE THE PROBLEM, IT IS VERY DANGEROUS. I HAVE A 5-YEAR EXTENDED WARRANTY AND GM IS REQUIRED TO WARRANT ALL ELECTRICAL PROBLEMS UNDER IT. FROM INTERNET RESEARCH, I CAN TELL THAT GM HAS MULTIPLE PROBLEMS WITH THE ELECTRICAL SYSTEMS IN THE 2003-2004 CAVALIERS AND I FEEL THIS IS ONE MORE MANIFESTATION OF THAT MANUFACTURING PROBLEM. *NM
NHTSA ODI #10112176
32,000 miles · Feb 1, 2005
Engine And Engine Cooling
WHILE DRIVING 30 MPH VEHICLE STALLED. CONSUMER MANAGED TO PULL OVER, AND HAD THE VEHICLE TOWED. DEALERSHIP REPAIRED THE PROBLEM. *AK
NHTSA ODI #10109489
Mileage unknown · Jan 26, 2005
Visibility
CONSUMER NOTICED THAT THE DEFROSTER WAS INOPERATIVE. IT FAILED TO DEFROST BOTH PASSENGER'S SIDE AND DRIVER'S SIDE WINDOWS, AND THE FRONT WINDSHIELD. THIS CAUSED POOR VISIBILITY TO THE DRIVER. VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION. THE CAUSE HAS NOT BEEN DETERMINED. *AK
NHTSA ODI #10108999
Mileage unknown · Jan 25, 2005
Exterior Lighting
04 V 524 000/REAR LIGHT BULB SOCKET ASSEMBLES: THE CONSUMER STATED, THE RECALL REMEDY WAS PERFORMED THREE TIMES ON THE LEFT REAR TAIL LIGHTS SOCKET AND TWO TIMES ON THE RIGHT TAIL LIGHTS SOCKET AND THE BULBS CONTINUED TO FAIL. THE DEALER WAS STILL UNABLE TO LOCATE THE PROBLEM. *JB
NHTSA ODI #10108785
44,000 miles · Jan 19, 2005
Visibility
THE CABLE WHICH CONTROLLED THE AIR FLOW FOR THE DEFROSTER/DEFOGGER BROKE. COULD NOT DEFROST FRONT WINDSHIELD, CAUSING POOR VISIBILITY WHILE DRIVING. DEALER WAS NOTIFIED. *AK *TC
NHTSA ODI #10105108
33,033 miles · Jan 14, 2005
Electrical System
CONSUMER EXPERIENCED ELECTRICAL PROBLEMS WITH VEHICLE. WHILE DRIVING, ALL THE LIGHTS CUT OFF INCLUDING THE INTERIOR LIGHTS. THE CONSUMER TOOK THE VEHICLE TO BE SERVICED THREE TIMES WITHIN THE LAST TWO WEEKS. THEY EXPLAINED TO HER THAT THEY COULD NOT FIND THE GLITCH AND UNTIL THEY DO SHE WOULD HAVE TO DRIVE THE VEHICLE AS IT IS. …
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CONSUMER EXPERIENCED ELECTRICAL PROBLEMS WITH VEHICLE. WHILE DRIVING, ALL THE LIGHTS CUT OFF INCLUDING THE INTERIOR LIGHTS. THE CONSUMER TOOK THE VEHICLE TO BE SERVICED THREE TIMES WITHIN THE LAST TWO WEEKS. THEY EXPLAINED TO HER THAT THEY COULD NOT FIND THE GLITCH AND UNTIL THEY DO SHE WOULD HAVE TO DRIVE THE VEHICLE AS IT IS. *JB THE THEFT SERVICE SHUTS DOWN IN THE VEHICLE. THE AIRBAG LIGHT CAME ON. WHEN THE DEFROSTER OR HEATER IS ON THE CONSUMER SMELLS A BURNING SMELL. *TC
NHTSA ODI #10105037
Mileage unknown · Jan 7, 2005
Exterior Lighting
REAR TURN SIGNAL ON 2003 FAILED FOR 5TH TIME IN 5 MONTHS. PROBLEM IS DESCRIBED IN NHTSA CAMPAIGN 04V524000. DEALER AND GM CUSTOMER SERVICE AT 1-800-222-1020 SAYS MY VIN DOES NOT APPLY TO THIS RECALL CAMPAIGN. MY VIN IS [XXX].*AK UPDATED 07/24/2012 *JS INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), …
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REAR TURN SIGNAL ON 2003 FAILED FOR 5TH TIME IN 5 MONTHS. PROBLEM IS DESCRIBED IN NHTSA CAMPAIGN 04V524000. DEALER AND GM CUSTOMER SERVICE AT 1-800-222-1020 SAYS MY VIN DOES NOT APPLY TO THIS RECALL CAMPAIGN. MY VIN IS [XXX].*AK UPDATED 07/24/2012 *JS INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA ODI #10105944
30,500 miles · Jan 3, 2005
Vehicle Speed Control
1/2/05-CAR WAS STOPPED AT AN INTERSECTION WHEN IT BEGAN TO LUNGE INTO TRAFFIC, CAR WAS PUT IN NEUTRAL WHERE IT CONTINUED TO LUNGE UNTIL A RIGHT TURN WAS MADE, CAR IS IN SERVICE TODAY 1/3/05. *AK
NHTSA ODI #10105655
Mileage unknown · Jan 1, 2005
Service Brakes, Hydraulic
I ALWAYS NOTICED ON MY 2003 CHEVROLET CAVALIER THAT THE LOW TRAC LIGHT WOULD PERIODICALLY COME ON WHEN I BRAKED. I THOUGHT THAT THIS WAS JUST BECAUSE IT WAS A NICER VEHICLE THAN MY PREVIOUS ONE (AN OLD FORD ESCORT). I RECENTLY TOOK MY CAR TO THE DEALERSHIP (INTEGRITY CHEVROLET IN PARMA HEIGHTS, OH) FOR 2 RECALLS. WHEN THEY FI…
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I ALWAYS NOTICED ON MY 2003 CHEVROLET CAVALIER THAT THE LOW TRAC LIGHT WOULD PERIODICALLY COME ON WHEN I BRAKED. I THOUGHT THAT THIS WAS JUST BECAUSE IT WAS A NICER VEHICLE THAN MY PREVIOUS ONE (AN OLD FORD ESCORT). I RECENTLY TOOK MY CAR TO THE DEALERSHIP (INTEGRITY CHEVROLET IN PARMA HEIGHTS, OH) FOR 2 RECALLS. WHEN THEY FINISHED DOING THE RECALL WORK, THEY INFORMED ME THAT MY FRONT BRAKES WERE LOW. I THOUGHT THAT WAS UNUSUAL SINCE THE CAR WAS ONLY 1 1/2 YEARS OLD AND HAD ONLY 23,000 MILES. A COUPLE OF DAYS LATER I INQUIRED TO THE DEALERSHIP ABOUT GETTING THE BRAKES REPAIRED. THEY INFORMED ME THAT THIS WAS JUST PART OF THE "NORMAL MAINTENANCE" WORK AND WAS NOT COVERED UNDER THE WARRANTY. I THOUGHT THIS WAS NOT USUAL MAINTENANCE SINCE A PERSON SHOULD NOT NEED NEW BRAKES AFTER 23,000 MILES. I TOOK MY CAR TO A LOCAL SERVICE CENTER A COUPLE OF DAYS LATER TO CHECK MY BRAKES. THEY INFORMED ME THAT NOT ONLY DID I NEED NEW BRAKES, BUT I ALSO NEEDED NEW ROTORS BECAUSE MINE WERE RUSTED. THIS TRIP TO THE LOCAL SERVICE CENTER COST ME $423.14. I AM STILL MAKING PAYMENTS ON THIS CAR AND IT IS ONLY 1 1/2 YEARS OLD! THIS SHOULD NOT BE HAPPENING TO A 1 1/2 YEAR OLD CAR WITH ONLY 23,000 MILES! THE SERVICE CENTER ATTENDANT HAD INFORMED ME THAT THEY HAD NOTICED THIS WITH MANY OF THE 2003 CHEVROLET CAVALIERS. THIS LEAD ME TO BELIEVE THAT THE PROBLEM WITH MY BRAKES AND ROTORS IS INDICATIVE OF A MANUFACTURING DEFECT! *JB
NHTSA ODI #10104890
100 miles · Dec 30, 2004
Exterior Lighting
HEADLIGHTS ARE GOING OUT COMPLETELY ON 2003 CHEVROLET CAVALIER. OK, WHOM, HAS WHAT LEGISLATOR, IN, WHOM'S BACK POCKET? THERE WAS A RECALL BY CHEVROLET IN NOVEMBER, OF 2004- I AM BETTING COMPLETELY VOLUNTARY, OF COURSE. THIS RECALL, WAS, FOR TAILLIGHTS AND LIGHTBULB GREASE. RIGHT, SOMEBODY GOING TO GET KILLED IN THOSE VEHICLES, I…
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HEADLIGHTS ARE GOING OUT COMPLETELY ON 2003 CHEVROLET CAVALIER. OK, WHOM, HAS WHAT LEGISLATOR, IN, WHOM'S BACK POCKET? THERE WAS A RECALL BY CHEVROLET IN NOVEMBER, OF 2004- I AM BETTING COMPLETELY VOLUNTARY, OF COURSE. THIS RECALL, WAS, FOR TAILLIGHTS AND LIGHTBULB GREASE. RIGHT, SOMEBODY GOING TO GET KILLED IN THOSE VEHICLES, IF THE HEADLIGHT PROBLEMS ARE NOT CORRECTED. HERE IS A HINT, READ THIER TSB REGARDING THE HEADLIGHTS DIMMING PROBLEM. WHAT A LOAD THAT IS. I WILL TELL YOU WHY, I THINK THEY PUT THAT TSB OUT. IT WAS JUST SIMPLY TO COVER THIER OWN YOU KNOW WHAT. I WONDER HOW MANY FIRES, OR DEATHS HAVE OCCURED DUE TO THE LIGHT HEARTED APPROACH GM HAS TOWARDS THE LIGHTING PROBLEMS ON THE 2003 MODELS? DON'T YOU LOVE HUBEROUS. HAVE YOU GONE TO YOUR DEALER ABOUT A SAFETY ISSUE LATELY. OH, CHECK OUT THE BRAKE ROTORS THERE IS STRESS AND HEAT FRACTURES AT LESS THAN THIRTY THOUSAND MILES. COME ON! ARE WE WAITING FOR 1000 WHEELS TO CATCH ON FIRE, OR JUST MY PREGNANT WIFE LOOSING CONTROL DUE THE SHIMMY. AH HECK, I'LL JUST GO BUY A AN OLD PINTO AND HAVE REAL EXPENSIVE LAWN ORNAMENT FULLY INSURED OF COURSE, FOR THE NEXT THREE LONG YEARS. DID I MENTION THE STEREO FACE BURNING ONES FINGERS, BUT THE DEALER SAYS, THAT WAS OK TOO. FORGET THE KICKBACKS AND DO YOUR JOBS. REMEMBER THE TAXPAYER AND PUBLIC SERVENT, NOT CORPORATION AND PUBLIC SERVENT. SLEEP WELL, I AM GLAD SOMEONE CAN. I GOT GO CHANGE SOME DIAPERS NOW. YEH, THREE KIDS; NONE OF THEM RIDE IN THAT DEATH TRAP.*AK
NHTSA ODI #10104754
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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