IllustrationHORN STOPPED WORK. WENT TO TAKE DAUGHTER TO GET LICENSE AND IT DIDN'T WORK. CHECKED FUSES AND STILL DID NOT WORK. I TOOK TO THE DEAL AND THEY SAID I HAD TO GET THE HORN MODULE AND AIR BAG REPLACED. I HAVEN'T HAD THE CAR THREE YEARS YET. *NM
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
Electrical System complaints
106 reports1. VEHICLE MADE A MOANING NOISE WHEN TURNING AT APPROXIMATELY 55,000 KMS (AND 3 YEARS OLD). REPLACED POWER STEERING PUMP AND STEERING RACK. 2. RANDOM CLUNKING FROM THE FRONT END AT APPROX. 56,000 KMS. REPLACED FRONT BEARINGS AND TRANSMISSION MOUNT. 3. CAR LOST POWER, HAD TO BE TOWED TO DEALERSHIP. DEALER COULDN'T FIND A PROBLE…
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1. VEHICLE MADE A MOANING NOISE WHEN TURNING AT APPROXIMATELY 55,000 KMS (AND 3 YEARS OLD). REPLACED POWER STEERING PUMP AND STEERING RACK. 2. RANDOM CLUNKING FROM THE FRONT END AT APPROX. 56,000 KMS. REPLACED FRONT BEARINGS AND TRANSMISSION MOUNT. 3. CAR LOST POWER, HAD TO BE TOWED TO DEALERSHIP. DEALER COULDN'T FIND A PROBLEM, INSISTED THE CAR WAS FINE. I INSISTED ON THEM TAKING IT OUT AGAIN. CAR BROKE DOWN, HAD TO BE TOWED BACK TO DEALER AGAIN. REPLACED CATALYTIC CONVERTER AND FUEL IGNITION SWITCH. 4. BURNED THROUGH 4L OF OIL AND PUFFED OUT BLACK SMOKE. DEALER COULDN'T LOCATE PROBLEM. HAPPENED AGAIN APPROX. 2000 KMS LATER. FAULTY PISTON RINGS, ENGINE REPLACED ENTIRELY. AT 61,000 KMS. NOW AT OVER $11,000 CDN WARRANTY REPAIRS ON A WELL MAINTAINED LOW MILEAGE CAR. 5. RANDOM CLUNKING NOISE IN FRONT IS BACK. GOING TO DEALER TOMORROW. WARRANTY: EXPIRED. *JB
DT*: THE CONTACT STATED THE TEMPERATURE GAUGE IN THE INSTRUMENT CLUSTER GOES ALL THE WAY AROUND WHICH INTERFERES WITH THE SPEEDOMETER'S READING. THE TWO NEEDLES SOMETIMES HIT EACH OTHER. ALSO, THE GAS GAUGE CONTINUES TO GO AROUND. THE DEALERSHIP TOLD THE CONTACT THAT THERE ARE TWO LOCATIONS IN THE UNITED STATES THAT CAN REPAIR…
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DT*: THE CONTACT STATED THE TEMPERATURE GAUGE IN THE INSTRUMENT CLUSTER GOES ALL THE WAY AROUND WHICH INTERFERES WITH THE SPEEDOMETER'S READING. THE TWO NEEDLES SOMETIMES HIT EACH OTHER. ALSO, THE GAS GAUGE CONTINUES TO GO AROUND. THE DEALERSHIP TOLD THE CONTACT THAT THERE ARE TWO LOCATIONS IN THE UNITED STATES THAT CAN REPAIR THE INSTRUMENT CLUSTER, AND IT WOULD HAVE TO BE SENT TO THEM. *AK UPDATED 2/9/2006 - *NM
DT*: THE CONTACT STATED WHILE DRIVING THE VEHICLE AT 65 MPH THE SPEEDOMETER WENT ERRATIC, AND THE TEMPERATURE GAUGE WENT UP TO 260 DEGREES. THE VEHICLE WAS TAKEN TO A LOCAL GARAGE, AND THEY DETERMINED THE INSTRUMENT CLUSTER PANEL WAS DEFECTIVE, AND THE VEHICLE NEEDED TO BE TAKEN TO A LOCAL DEALERSHIP FOR REPAIRS. *AK
DT: THE CONTACT STATED THE HORN STOPPED WORKING. THE VEHICLE WAS TAKEN TO A DEALERSHIP, AND THEY STATED THE HORN MODULE WENT OUT. THE AIRBAG WOULD HAVE TO BE REPLACED TO REPAIR THE PROBLEM. THEREFORE, NO REPAIRS HAVE BEEN MADE. *AK
DT: 2003 CHEVROLET CAVALIER. THE CONTACT'S DAUGHTER WAS DRIVING THE VEHICLE. WHILE DRIVING, ALL OF THE LIGHTS ON THE DASHBOARD CAME ON AND THEN WENT OFF. ABOUT AN HOUR LATER THE CONTACT'S VEHICLE CRASHED BECAUSE SHE COULD NOT STEER IT. THE CONTACT STATED IT WAS A CLEAR DAY, THERE WAS NOT A LOT OF TRAFFIC , AND NO REASON FO…
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DT: 2003 CHEVROLET CAVALIER. THE CONTACT'S DAUGHTER WAS DRIVING THE VEHICLE. WHILE DRIVING, ALL OF THE LIGHTS ON THE DASHBOARD CAME ON AND THEN WENT OFF. ABOUT AN HOUR LATER THE CONTACT'S VEHICLE CRASHED BECAUSE SHE COULD NOT STEER IT. THE CONTACT STATED IT WAS A CLEAR DAY, THERE WAS NOT A LOT OF TRAFFIC , AND NO REASON FOR HER TO LOSE CONTROL. THERE WAS A CODE FOUND, B2625 FOR DISPLAY DIMMING PULSE. IT APPEARED TO BE A PROBLEM WITH THE LIGHTING DISPLAY. THERE NO INDICATION THAT THERE WAS POWER FAILURE AT THE TIME OF THE ACCIDENT. A POLICE REPORT WAS TAKEN. THE CONTACT'S DAUGHTER SUSTAINED BRUISES AND HAD A BACKACHE. THERE HAS NOT BEEN ANY REPAIRS TO THE VEHICLE AT THIS TIME. *AK UPDATED 11/29/2005 - *NM *JB
MY SPEEDOMETER IS NOT READING CORRECTLY AT TIMES THAT ARE NOT PREDICTABLE. TODAY FOR INSTANCE IT HAS LOST SPEED BY READING AT 5 MPH WHEN I AM DRIVING AT 40 MPH! IT HAS EVEN READ AT 85 MPH WHEN I WAS ONLY DRIVING AT 50 MPH! I HAVE TAKEN THIS PROBLEM TO DEALERSHIP AND STILL NO RESULT. NOW MY TEMPERATURE DIAL IS GOING BONKERS. I H…
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MY SPEEDOMETER IS NOT READING CORRECTLY AT TIMES THAT ARE NOT PREDICTABLE. TODAY FOR INSTANCE IT HAS LOST SPEED BY READING AT 5 MPH WHEN I AM DRIVING AT 40 MPH! IT HAS EVEN READ AT 85 MPH WHEN I WAS ONLY DRIVING AT 50 MPH! I HAVE TAKEN THIS PROBLEM TO DEALERSHIP AND STILL NO RESULT. NOW MY TEMPERATURE DIAL IS GOING BONKERS. I HAVE SEEN SEVERAL POST ON SITES ABOUT THE DASHBOARD/CAR ELECTRICAL PROBLEMS! I NOW HAVE MY FIRST SPEEDING TICKET DUE TO THE RESULT OF THIS! *JB
JUST WANTED TO CLARIFY MY CALL RESULTING IN ODI NUMBER 10133041. ACCORDING TO THE MECHANIC, PRIOR TO THE BELT BREAKING, MY CAR'S ALTERNATOR HAD A "HARD SPOT". THIS MEANS THAT IT WOULD SEIZE AND LET GO. MY UNDERSTANDING IS THAT THE ALTERNATOR SHOULD NOT SEIZE UNLESS THERE IS A COLLISION WHICH IN TURN STOPS THE ENGINE. THIS…
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JUST WANTED TO CLARIFY MY CALL RESULTING IN ODI NUMBER 10133041. ACCORDING TO THE MECHANIC, PRIOR TO THE BELT BREAKING, MY CAR'S ALTERNATOR HAD A "HARD SPOT". THIS MEANS THAT IT WOULD SEIZE AND LET GO. MY UNDERSTANDING IS THAT THE ALTERNATOR SHOULD NOT SEIZE UNLESS THERE IS A COLLISION WHICH IN TURN STOPS THE ENGINE. THIS CAR HAS NEVER BEEN IN AN ACCIDENT. *AK THIS RANDOM SEIZING, I BELIEVE, IS WHAT CAUSED MY "UNDIPLOMATIC", STEERING AND BRAKING PROBLEMS - WITH LOSS OF CONTROL RANGING FROM 1/2 SECOND TO 2 SECONDS AT A TIME. ON THE REPORT ASSOCIATED WITH THE ALTERNATOR REPAIR, I AGAIN REPORTED BRAKING PROBLEMS (NOT JUST THE DOCUMENTED NOISE), AND THE ODDBALL SENSATION IN THE STEERING WHEEL. BOTH LINES OF COMPLAINT WERE ATTRIBUTED TO THE SEIZING UP OF THE ALTERNATOR. TO ME, THIS MEANS THAT MY LIFE, AND THE LIFE OF ANYONE ELSE ON THE ROAD WITH ME - WAS AND STILL IS STILL AT THE MERCY OF A WEIRD ALTERNATOR, WHOSE INTERMITTENT FAILURES RESULT IN LOSS OF POWER TO THE STEERING PUMP, AND THE BRAKES - RESULTING IN COMPLETE LOSS OF CONTROL OF THE CAR UNTIL THE BACKUP KICKS IN - WHICH TAKES FROM 1/2 SECOND TO 2 SECONDS. I WISH TO MAKE VERY CLEAR - I DO NOT BLAME THE DEALER FOR LACK OF ABILITY TO ADEQUATELY REPAIR WHAT IS AN INHERENT DESIGN FLAW. IN ADDITION, IN THE COURSE OF RESEARCH, I HAVE LEARNED THAT MOST ALL NEW CARS REGARDLESS OF MANUFACTURER ARE DESIGNED THE SAME WAY. THIS IS A SERIOUS HAZARD, AND NEEDS TO BE ADDRESSED ON AN INDUSTRY WIDE SCALE. AT THIS STAGE, STEERING, ACCELERATION, AND BRAKING ARE ALL ERRATIC. SOUND IN THE FRONT TIRES IS LIKE A CLIP-CLOP. I AM NOT A MECHANIC, BUT IN READING THE DESCRIPTIONS PLACED HERE, I MUST ALSO WONDER IF THE CRASHES AND AIRBAG FAILED DEPLOYMENTS IN SEVERAL POSTS WERE ALSO DUE TO A SEIZING ALTERNATOR PRIOR TO THE MVA.*AK
DT: THE CONSUMER OWNS A 2003 CHEVROLET CAVILER. WAS LOSING CONTROL OF THE STEERING AND THE BRAKES. IT STARTED IN THE WINTER. THE CONSUMER STATED THE DIRECTION THAT CAR WAS HEADED WAS THE WAY IT STAYED. ALSO, SHE NOTICED THAT THERE WAS A HUM IN THE STEERING WHEEL WHICH LASTED A COUPLE OF SECONDS EACH TIME. THE CONSUMER C…
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DT: THE CONSUMER OWNS A 2003 CHEVROLET CAVILER. WAS LOSING CONTROL OF THE STEERING AND THE BRAKES. IT STARTED IN THE WINTER. THE CONSUMER STATED THE DIRECTION THAT CAR WAS HEADED WAS THE WAY IT STAYED. ALSO, SHE NOTICED THAT THERE WAS A HUM IN THE STEERING WHEEL WHICH LASTED A COUPLE OF SECONDS EACH TIME. THE CONSUMER CONTACTED THE DEALER, AND THEY SAID THAT IT DID NOT SOUND TO THEM AS DANGEROUS. A COUPLE OF MONTHS LATER THE PROBLEM FINALLY CAME TO AHEAD IN JUNE. LIGHTS CAME ON THE DASHBOARD. THE BELT BROKE, AND THE ALTERNATOR SEIZED. WHEN THE CAR WAS REPAIRED BY THE DEALER THEY CONCLUDED THE ALTERNATOR AND THE BELT MALFUNCTIONED. ALSO HEARD A GRINDING NOISE IN THE BRAKES. THE DEALER NEVER DID ANY REPAIRS TO THE STEERING. THE CONSUMER SAID THAT THE KEY WAS HOT AFTER IT HAD BEEN IN THE IGNITION. AND THE STEERING WHEEL WAS TIGHT WHEN TURNING TO THE RIGHT. THE CAR WENT BACK TO THE DEALER , AND SHE DID NOT HAVE THE TIGHTNESS TO THE STEERING. BUT, THE CAR WAS STILL PULLING TO THE RIGHT. THE BRAKES WERE SPONGY. THERE WAS A POPPING SOUND IN THE FRONT WHEEL. THERE WAS A DELAY IN THE SPEED OF THE CAR. AND ALMOST HAD A COLLISION. *AK
CHEVROLET CAVALIER 2003, PROBLEM EXIST WITH THE PASSENGER SIDE BLINKER/BRAKE LIGHT CONTINUES TO OPERATE INCORRECTLY. *BF THE STARTER CYLINDER WAS REPLACED. *JB THE DEALER REPLACED THE BRAKE LIGHT BULB AND BLINKER BULB ON SEVERAL OCCASIONS.
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.