NHTSA owner reports · September 18, 2026 snapshot.
Suspension complaints
22 reportsClear category filter113,000 miles · Jun 26, 2016
Suspension
MY 2003 CHEVROLET CAVALIER RECENTLY BEGAN TO MAKE A CLUNKING NOISE, WHICH CAN ALSO BE FELT, IN THE FRONT END. WHEN I PUT IT UP ON A LIFT, I NOTICED THAT THE SUB-FRAME WAS RUSTING (DETERIORATING). I KNOW IT IS 13 YEARS OLD, BUT MY PARENTS OWNED A 1989 CAVALIER Z24 FOR 20 YEARS, AND THEY DIDN'T HAVE ANY PROBLEMS WITH ITS FRAME. …
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MY 2003 CHEVROLET CAVALIER RECENTLY BEGAN TO MAKE A CLUNKING NOISE, WHICH CAN ALSO BE FELT, IN THE FRONT END. WHEN I PUT IT UP ON A LIFT, I NOTICED THAT THE SUB-FRAME WAS RUSTING (DETERIORATING). I KNOW IT IS 13 YEARS OLD, BUT MY PARENTS OWNED A 1989 CAVALIER Z24 FOR 20 YEARS, AND THEY DIDN'T HAVE ANY PROBLEMS WITH ITS FRAME. I'VE READ THAT OTHER PEOPLE HAVE HAD THIS SAME ISSUE WITH THEIR 2003 CHEVY CAVALIERS. WHY IS THIS? WHY HAS THERE NOT BEEN A RECALL? MY FAMILY HAS OWNED SEVERAL NEW AND USED VEHICLES, ALL GM, AND WE HAVE NEVER SEEN A SUB-FRAME RUST TO THIS EXTENT. WE ARE A GM FAMILY AND ARE EXTREMELY DISAPPOINTED IN GM'S LACK OF RESPONSE TO THIS SAFETY HAZARD.
NHTSA ODI #10876674
130,000 miles · Mar 17, 2016
Electrical SystemSteeringSuspension
INSTRUMET CLUSTER PROBLEMS FOR A FEW YEARS. FUEL SENDING UNIT HAS BEEN REPLACED AT ABOUT 52,000 MILES AFTER QUITING TWICE WHILE DRIVING HIGHWAY SPEED OF 55 MPH. DEALER CLAIMED THE CAR QUIT BECAUSE OF A BAD BATTERY THE FIRST TIME AND DID NOT DIAGNOSE THE PROBLEM CORRECTLY. IT WAS NOT THE BATTERY. THE FUEL SENDING UNIT INTERMI…
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INSTRUMET CLUSTER PROBLEMS FOR A FEW YEARS. FUEL SENDING UNIT HAS BEEN REPLACED AT ABOUT 52,000 MILES AFTER QUITING TWICE WHILE DRIVING HIGHWAY SPEED OF 55 MPH. DEALER CLAIMED THE CAR QUIT BECAUSE OF A BAD BATTERY THE FIRST TIME AND DID NOT DIAGNOSE THE PROBLEM CORRECTLY. IT WAS NOT THE BATTERY. THE FUEL SENDING UNIT INTERMITTENTLY READS WELL BEYOND FULL AND INTERFEARS WITH THE TEMPERATURE GAGE FUNCTION. NOW SPEEDOMETER IS STUCK AT 85 MPH WHILE TURNED OFF. I WAS DRIVING WITH THE CRUISE DOING 67 MPH, I SLOWED DOWN TO MAKE A TURN AT AN AT GRADE INSECTION TO A ROAD POSTED AT 55 MPH. I COMPLETED THE TURN AND SPED UP. THE SPEEDOMETER READ 58 MPH BUT IT FELT LLIKE I WAS GONG ABOUT 30 MPH. I STOPPED AT ANOTHER INTERSECTION AND THE SPEED DROPPED TO 40 MPH. I MADE THE TURN AND ACELERATED AND THE SPEED WENT TO 110 MPH BUT I WAS NOT GOING NEAR THAT FAST. THE CAR IS IN DRIVEWAY TURNED OFF BUT THE SPEEDOMETER READS 85 MPH. MOST RECENT ISSUE IS STEERING RACK AND K-FRAME RUSTED OUT AND NEEDED TO BE REPLACED. MECHANIC STATED HE NEVER SAW A STEERING RACK RUST OUT OR A K FRAME RUSTED AS BAD AS THE ONE ON THIS VEHICLE. WE ARE THE ORIGINAL OWNERS.
NHTSA ODI #10850333
200,000 miles · Feb 9, 2016
StructureSuspension
I HAVE NOTICED A LOT AND I MEAN A LOT OF THESE CAVALIERS HAVE HAD HORRIBLE FRAME PROBLEMS I USE TO WORK ON CARS EVERYDAY UNTIL THE LAST YEAR WHEN I GOT OUT OF THE MECHANICS FIELD AN NOW I OWN A 03 CHEVY CAVALIER ITS A TWO DOOR 5 SPEED 2.2 I WAS ON MY WAY HOME FROM THE STORE AND I FELT SOMETHING RUBBING SO I STOPPED AN GOT OUT TO…
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I HAVE NOTICED A LOT AND I MEAN A LOT OF THESE CAVALIERS HAVE HAD HORRIBLE FRAME PROBLEMS I USE TO WORK ON CARS EVERYDAY UNTIL THE LAST YEAR WHEN I GOT OUT OF THE MECHANICS FIELD AN NOW I OWN A 03 CHEVY CAVALIER ITS A TWO DOOR 5 SPEED 2.2 I WAS ON MY WAY HOME FROM THE STORE AND I FELT SOMETHING RUBBING SO I STOPPED AN GOT OUT TO FIND OUT MY K FRAME WAS HORRIBLY ROTTED AN BROKE NOW THIS VEHICLE IS 13 YEARS OLD BUT AS ROTTED OUT AS IT WAS IT WASN'T SOMETHING THAT JUST HAPPENED ITS BEEN BAD I WAS JUST THE LUCKY OWNER THAT THE FRAME GAVE OUT ON AN I DEMAND TO KNOW WHY THIS ISN'T A RECALL ANOTHER THING IS I OWNED A 98 FORD F150 WHICH HAD RECALLS AN WHEN I WAS SENT THE LETTER ABOUT THE RECALLS I ASKED FORD WHY THE FRAMES ON THE F150 OR RANGER WASN'T A RECALL THEY HAD NO ANSWER. I PUT MY CHILD IN THESE AUTO MAKERS CARS AND TRUST THEIR WORK TO KEEP HIM SAFE BUT THEY HAVE NO ANSWER FOR WHY ONE OF THE MOST IMPORTANT PART ON THE WHOLE VEHICLE IS FALLING APART. I DON'T KNOW IF THEY NEED TO USE STAINLESS STEEL, ALUMINUM, OR WHAT BUT IT NEEDS FIXED OR THE VEHICLES NEED REIMBURSED AN CRUSHED. I COULD OF BEEN DOING 70 MPH DOWN THE HIGHWAY WITH MY WOMAN AN SON IN THE CAR AN THE FRAME COULD OF WENT AND KILLED US ALL. IS THAT WHAT ITS GONNA TAKE TO GET THIS [XXX] FIXED SOMEONE ELSE TO DIE/HURT. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
NHTSA ODI #10825225
Mileage unknown · Dec 14, 2015
Service BrakesSteeringSuspension
METAL ON METAL NOISE FOUND OUT SHOES AND ROTORS ARE DAMAGEDDAMAGED. I HAVE NO MONEY. V CAN'T FIX THIS. SMELL INSIDE OF LEAK. TEMP RUNNING HIGH. 200.
NHTSA ODI #10810161
60,000 miles · Jun 24, 2010
Air BagsFuel System, GasolineSuspensionCrash
2003 CHEVROLET CAVALIER- AT 64,000 MILES FUEL PUMP DIED WHILE PARKED AT A STORE UPON RESTART $700.00 REPLACEMENT. AT APPROXIMATELY 60,000 MILES FRONT CLUNKING NOISE STARTED, DEALER COULD NEVER FIND A PROBLEM, NOW AT 76,000 MILES, HAVING FRONT UPPER STRUT MOUNTS REPLACED. FOUND ALOT OF COMPLAINTS ONLINE ABOUT SAME ISSUES. I DE…
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2003 CHEVROLET CAVALIER- AT 64,000 MILES FUEL PUMP DIED WHILE PARKED AT A STORE UPON RESTART $700.00 REPLACEMENT. AT APPROXIMATELY 60,000 MILES FRONT CLUNKING NOISE STARTED, DEALER COULD NEVER FIND A PROBLEM, NOW AT 76,000 MILES, HAVING FRONT UPPER STRUT MOUNTS REPLACED. FOUND ALOT OF COMPLAINTS ONLINE ABOUT SAME ISSUES. I DETERMINED CAUSE OF FRONT CLUNK ON MY OWN. ALSO, WAS IN COLLISION THAT INVOLVED FRONT DRIVER SIDE, DOWN DRIVER SIDE FRONT FENDER, AIRBAGS DID NOT DEPLOY, DON'T KNOW IF THEY SHOULD HAVE. NOONE WAS HURT, WAS SLOW SPEED CRASH. STILL CANNOT BELIEVE NO RECALL ON FUEL PUMP OR FRONT SUSPENSION. APPARENTLY GM DOESN'T WANT TO FOOT THE 700.00 BILL FOR THE FUEL PUMP DEFECT. *TR
NHTSA ODI #10339834
49,238 miles · Aug 22, 2008
Suspension
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT'S DAUGHTER HAD A FLAT TIRE AND WENT TO A TIRE SHOP. BOTH REAR TIRES HAD TO BE REPLACED BECAUSE THEY WERE WORN DOWN TO THE METAL. THE AUTO SHOP COULD NOT ALIGN THE VEHICLE BECAUSE THE REAR AXLE WAS BENT. SINCE THE VEHICLE WAS PURCHASED IN NOVEMBER OF 2007, BOTH REAR T…
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TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT'S DAUGHTER HAD A FLAT TIRE AND WENT TO A TIRE SHOP. BOTH REAR TIRES HAD TO BE REPLACED BECAUSE THEY WERE WORN DOWN TO THE METAL. THE AUTO SHOP COULD NOT ALIGN THE VEHICLE BECAUSE THE REAR AXLE WAS BENT. SINCE THE VEHICLE WAS PURCHASED IN NOVEMBER OF 2007, BOTH REAR TIRES HAVE BEEN REPLACED TWICE. THE REAR AXLE WAS BENT BEYOND THE POINT WHERE IT COULD BE ADJUSTED; THEREFORE, IT NEEDS TO BE REPLACED. THE AXLE WAS THE CAUSE OF THE REAR TIRE FAILURE. THE CURRENT MILEAGE WAS 52,000 AND FAILURE MILEAGE WAS 49,238.
NHTSA ODI #10239387
55,000 miles · Apr 14, 2008
Suspension
I HAVE HAD A CONTINUING PROBLEM WITH A SINGLE PART ON THIS VEHICLE THAT IS PREMATURELY WEARING OUT. I CALLED CHEVROLET TO EXPRESS MY CONCERN ABOUT THIS ISSUE AND THAT I WAS 99% SURE THAT IT HAD FAILED AGAIN (FOR THE 4TH TIME), AND WAS IN NEED OF REPLACEMENT (FOR THE 4TH TIME). BECAUSE I HAD THE 'RIGHT UPPER STRUT MOUNT & BEARI…
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I HAVE HAD A CONTINUING PROBLEM WITH A SINGLE PART ON THIS VEHICLE THAT IS PREMATURELY WEARING OUT. I CALLED CHEVROLET TO EXPRESS MY CONCERN ABOUT THIS ISSUE AND THAT I WAS 99% SURE THAT IT HAD FAILED AGAIN (FOR THE 4TH TIME), AND WAS IN NEED OF REPLACEMENT (FOR THE 4TH TIME). BECAUSE I HAD THE 'RIGHT UPPER STRUT MOUNT & BEARING' REPLACED 3 PREVIOUS TIMES, I FELT THAT CHEVROLET SHOULD BE MADE AWARE OF A DEFECTIVE PART AND ALSO HOPED THAT CHEVROLET WOULD PAY FOR THIS REPLACEMENT. IT IS MY OPINION (AND HAVE NOT BEEN PROVEN OTHERWISE BY CHEVROLET OR ANYBODY AT CHEVROLET), THAT THE UPPER STRUT MOUNT IS AN AUTOMOTIVE PART THAT SHOULD AT LEAST LAST 100,000 MILES IF NOT LONGER. IT IS ALSO MY OPINION THAT THIS PART SHOULD NOT HAVE TO BE REPLACED 4 TIMES IN LESS THAN 60,000 MILES. *TR
NHTSA ODI #10224432
40,000 miles · Feb 24, 2007
SuspensionVisibility
FRONT DRIVER SIDE WINDOW FAILURE, STARTED GOING DOWN A QUARTER TO HALF WAY DOWN AND STOPPING THEN WHEN YOU TRY TO PUT IT UP IT ONLY GOES UP LIKE A INCH AND YOU HAVE TO WAIT A LITTLE WHILE AND KEEP DOING THAT UNTIL THE WINDOW IS COMPLETELY UP. SECOND THERE IS A CLUCKING NOISE COMING FROM THE FRONT AT LOW SPEEDS INCLUDING WHEN TUR…
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FRONT DRIVER SIDE WINDOW FAILURE, STARTED GOING DOWN A QUARTER TO HALF WAY DOWN AND STOPPING THEN WHEN YOU TRY TO PUT IT UP IT ONLY GOES UP LIKE A INCH AND YOU HAVE TO WAIT A LITTLE WHILE AND KEEP DOING THAT UNTIL THE WINDOW IS COMPLETELY UP. SECOND THERE IS A CLUCKING NOISE COMING FROM THE FRONT AT LOW SPEEDS INCLUDING WHEN TURNING OR GOING OVER A BUMP. *JB
NHTSA ODI #10183417
55,000 miles · Sep 28, 2006
Electrical SystemEngine And Engine CoolingFuel System, Gasoline
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 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
NHTSA ODI #10169531
1,392 miles · Aug 16, 2005
Electrical SystemEngine And Engine CoolingService Brakes, Hydraulic
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
NHTSA ODI #10133041
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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