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
What owners actually said
678 reports
6,500 miles · Mar 24, 2004
Electrical SystemEquipmentSuspension
THE TIRES SHAKE AND VIBRATE AROUND SIXTY MILES/HR. SO I TOOK THEM TO SAM'S CLUB TO THEIR TIRE CENTER IN DECEMBER OF 2003. THEY ROTATED AND BALANCED THE TIRES. I DROVE THE CAR FOR ONE MONTH, THEN THE TIRES STARTED DOING THE SAME THING OVER AGAIN. ABOUT ONE MONTH LATER, I WENT BACK TO SAM'S CLUB AND THEY BALANCED MY TIRES AGAIN…
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THE TIRES SHAKE AND VIBRATE AROUND SIXTY MILES/HR. SO I TOOK THEM TO SAM'S CLUB TO THEIR TIRE CENTER IN DECEMBER OF 2003. THEY ROTATED AND BALANCED THE TIRES. I DROVE THE CAR FOR ONE MONTH, THEN THE TIRES STARTED DOING THE SAME THING OVER AGAIN. ABOUT ONE MONTH LATER, I WENT BACK TO SAM'S CLUB AND THEY BALANCED MY TIRES AGAIN. SO HERE IT IS MARCH OF 2004, THE TIRES ARE DOING THE SAME THING AGAIN SHAKING AND VIBRATING AROUND SIXTY MILES/HR. I CALLED GOODYEAR , THEY TOLD ME TO BRING THE CAR IN. THEY LOOKED AT THE TIRES, AND SAID THAT THE REAR TIRES WERE WORN ON THE INSIDE, AND THAT I WOULD HAVE TO TAKE THE CAR BACK TO THE DEALERSHIP TO GET THE TIRES FIXED. THEY COULD NOT DIAGNOSE THE SPECIFIC ORIGIN OF THE VIBRATION. BASICALLY, FOR A BRAND NEW CAR, WE SHOULD NOT HAVE THESE KIND OF PROBLEMS AT 24,000 MILES (AS STATED BY MECHANICS FROM GOODYEAR, SAM'S CLUB AND FIRESTONE). 5. CRUISE CONTROL SWITCH- IF RIGHT TURN SIGNAL IS USED WHEN CRUISE CONTROL IS ACTIVATED, THE CRUISE CONTROL WILL AUTOMATICALLY DEACTIVATE ITSELF. 6. POWER FAILURE- CAR ALL OF A SUDDEN LOST POWER WHILE AT A STOPLIGHT. 7. A/C & HEATER- A/C AND HEATER MAKE LOUD NOISE. 8. REAR TURN SIGNAL LIGHT BULBS BURNED OUT 4 TIMES ON EACH SIDE. GM REPLACEMENT BULBS LAST ONLY 1 TO 1 1/2 MONTH. *NM
WHEN APPLYING THE BRAKES AT NIGHT, THE HEADLIGHTS AND DASH LIGHTS DIM TO A SOFTER SHADE OF LIGHT. I HAVE ALSO CHANGED THE REAR SINGLE LIGHTS IN MY CAR THREE TIMES IN THE PAST 6 MONTHS. THIS CAR HAS A BAD BRAKE PROBLEM. THE FRONT OF THE CAR SHAKES VERY BAD WHEN YOU APPLY THE BRAKES WHILE EXITING A HIGHWAY. CITY DRIVING IS NOT …
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WHEN APPLYING THE BRAKES AT NIGHT, THE HEADLIGHTS AND DASH LIGHTS DIM TO A SOFTER SHADE OF LIGHT. I HAVE ALSO CHANGED THE REAR SINGLE LIGHTS IN MY CAR THREE TIMES IN THE PAST 6 MONTHS. THIS CAR HAS A BAD BRAKE PROBLEM. THE FRONT OF THE CAR SHAKES VERY BAD WHEN YOU APPLY THE BRAKES WHILE EXITING A HIGHWAY. CITY DRIVING IS NOT AS BAD, BUT WHEN THE BRAKES GET WARMED UP THEY PULSATE WHEN I COME TO A STOP. AT THE END OF THE DAY, I PULL MY CAR INTO MY DRIVEWAY AND THE FIRST THING I SMELL WHEN I GET OUT IS A BURNING SMELL FROM THE BACK BRAKES. I CALLED THE FUCILLO CHEVY SERVICE DEPARTMENT IN DECEMBER 2003. I TALKED TO A SERVICEMAN ABOUT MY BRAKE PROBLEM. HE TOLD ME THAT MY PULSATING BRAKES IS THE ABS SYSTEM WORKING IN THE SNOW. NOW THE ROADS ARE DRY AND MY BRAKES ARE STILL PULSATING. I COULD NOT FIND ANYTHING IN MY ORIGINAL PAPERWORK ON MY CAR SHOWING THAT IT HAS THE ABS SYSTEM. NOW MY BRAKES ARE SHOT. THE CAR HAD ONLY 6500 HUNDRED MILES ON IT WHEN I FIRST CALLED IN DECEMBER OF 2003. IN JUNE OF 2003, I BOUGHT THIS CAR AND TEST DROVE IT. THE CAR SEEMED TO BE A GOOD CAR, EXCEPT FOR THE NOISE THAT I HEARD COMING FROM THE FRONT LEFT TIRE AREA. IT SOUNDED LIKE A RUBBER BAND WHEN IT SNAPS. I BROUGHT IT UP TO MY SALESMEN ROCKY FROM THE CHEVY DEPARTMENT. HE TOLD ME THAT IT'S A NEW CAR. NOW WHEN THE FRONT TIRES ARE TURNED TO THE RIGHT, IT MAKES A CRUNCHING NOISE. WHEN I DRIVE OVER ANY BUMP AT ANY SPEED, IT FEELS LIKE THERE ARE NO SHOCKS OR STRUTS ON THIS CAR AND MAKES A BAD CLUNKING SOUND. *NM
NHTSA ODI #10063761
Mileage unknown · Mar 19, 2004
Exterior LightingCrash
I AM A GM TECHNICIAN. GM IS HAVING A HUGE PROBLEM WITH "J" BODY CARS WITH NEW BODY STYLE. (CAVILER, SUNFIRE YEAR 2001-CURRENT) THE PROBLEM IS WITH POOR TERMINAL CONTACT WITH THE REAR BULBS DUE TO DEFECTIVE BULB SOCKETS. THE RESULT IS LOSS OF REAR TURN SIGNALS AND BRAKE LAMPS ON ONE OR OFTEN BOTH SIDES. THIS PROBLEM AFFECTS CARS …
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I AM A GM TECHNICIAN. GM IS HAVING A HUGE PROBLEM WITH "J" BODY CARS WITH NEW BODY STYLE. (CAVILER, SUNFIRE YEAR 2001-CURRENT) THE PROBLEM IS WITH POOR TERMINAL CONTACT WITH THE REAR BULBS DUE TO DEFECTIVE BULB SOCKETS. THE RESULT IS LOSS OF REAR TURN SIGNALS AND BRAKE LAMPS ON ONE OR OFTEN BOTH SIDES. THIS PROBLEM AFFECTS CARS OFTEN WITH LESS THEN 1000 MILES. IT IS A HUGE PROBLEM AND OUR SHOP MUST FIX 8 CARS A WEEK ON AVERAGE FOR THIS PROBLEM AND WE ARE NOT A LARGE GM SHOP. NOT HAVING REAR TURN SIGNALS OR BRAKE LAMPS IS SERIOUS FOR RISK OF REAR-END COLLISIONS.*AK
NHTSA ODI #10062651
8,000 miles · Mar 12, 2004
SuspensionCrash
WITH ONLY .5 INCHES OF SNOW MY CAR (A 2003 CHEVY CAVALIER) LOST COMPLETE CONTROL AND SMASHED INTO THE CURB. THIS WAS WHILE TRAVELING AT LESS THAN 10MPH. I FEEL THE COMBINATION OF 16" TIRES AND THE SPORTS SUSPENSION (BOTH STANDARD ON THE CAR) WAS THE CAUSE OF THE ACCIDENT. *AK
NHTSA ODI #10062019
9,500 miles · Mar 11, 2004
Exterior Lighting
BRAKE LIGHT/TURN SIGNAL BULBS HAVE BURNED OUT 4 TIMES(LEFT 2 TIMES, RIGHT 2 TIMES) IN THE LAST 2 MONTHS.*AK
NHTSA ODI #10061942
15 miles · Feb 26, 2004
Electrical SystemExterior LightingVisibility
WHILE DRIVING AT ANY SPEED HEATER DID NOT WORK. VEHICLE WAS TAKEN TO THE DEALER, AND HEATER WAS REPLACED. ALSO, ON TWO DIFFERENT OCCASIONS DEALER REPLACED WIRING HARNESS AND CONNECTION WIRES. ON ANOTHER OCCASION ENTIRE BRAKE LIGHT ASSEMBLY WAS REPLACED ALONG WITH THE SOCKETS. IN ALL, VEHICLE HAD BEEN TO THE DEALER SIX…
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WHILE DRIVING AT ANY SPEED HEATER DID NOT WORK. VEHICLE WAS TAKEN TO THE DEALER, AND HEATER WAS REPLACED. ALSO, ON TWO DIFFERENT OCCASIONS DEALER REPLACED WIRING HARNESS AND CONNECTION WIRES. ON ANOTHER OCCASION ENTIRE BRAKE LIGHT ASSEMBLY WAS REPLACED ALONG WITH THE SOCKETS. IN ALL, VEHICLE HAD BEEN TO THE DEALER SIX TIMES IN SEVEN MONTHS.*AK
NHTSA ODI #10059837
Mileage unknown · Feb 25, 2004
Exterior Lighting
2003 CHEVROLET CAVALIER PURCHASED NEW AUGUST 23, 2003 BILL HEARD CHEVROLET,COLUMBUS GA. BRAKE LIGHT HAVE BURNED OUT TWICE SINCE THAT DATE. ONCE IN NOVEMBER 2003 AND AGAIN IN FEBRUARY 2004.*AK
NHTSA ODI #10058987
Mileage unknown · Feb 23, 2004
EquipmentExterior LightingSteering
I BOUGHT THE CAR BRAND NEW ARROUND 04/2003 CHEVROLET CAVALIER 2003 SINCE THEN I REPORTED SEVERAL TIMES BACK TO THE DEALER SHIP WITH THE FOLLOWING PROBLEMS:DRIVETRAIN - CLUNK NOISE DURING LOW SPEED TURNS A/C - DIFFICULT MODE/TEMPERATURE SETTING OPERATION . STEERING - MOMENTARY LOSS OF POWER ASSIST. STEERING - RATTLE/KNOCK WHEN…
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I BOUGHT THE CAR BRAND NEW ARROUND 04/2003 CHEVROLET CAVALIER 2003 SINCE THEN I REPORTED SEVERAL TIMES BACK TO THE DEALER SHIP WITH THE FOLLOWING PROBLEMS:DRIVETRAIN - CLUNK NOISE DURING LOW SPEED TURNS A/C - DIFFICULT MODE/TEMPERATURE SETTING OPERATION . STEERING - MOMENTARY LOSS OF POWER ASSIST. STEERING - RATTLE/KNOCK WHEN TURNING WHEELS - FRONT/REAR WHEEL SQUEAKING NOISE ---ALL THOSE COMPLAINTS ARE NEVER BEEN TAKEN CARE OFF - THEY ALLWAYS HAD SOME "LOW EXCUSES FOR ME - LIKE THE WHEATER/RAIN/DIRT ON THE WHEELS (I LIVE IN THE CITY ...NOT ON A DIRT ROAD..) ANYWAY THE ONLY COMPLAINT THEY TAKEN SERIOUS IS THAT I BROUGHT IN THE CAR NOW FOR THE 3RD TIME TO REPAIR THE RIGHT SIGNAL LIGHT - LAST TIME JUST TODAY! I REPORTED AGAIN ALL THE OTHER PROBLEMS, WITH THE SUCESS THAT THEY AT LEAST ORDERD NOW A "NEW PART" FOR THE A/C, EVERYTHING ELSE IS AGAIN BEEN "PLAYED" DOWN. HONESTLY, I'M GETTING TIRED OF HAVING SO MUCH TROUBLE WITH A NEW CAR. BRINGING IT TO THE DEALERSHIP ALWAYS COST ME A NEARLY A WHOLE DAY OF MISSING WORK. I WOULD LIKE TO KNOW IF THERE IS ANY WAY TO FIX ALL TJOSE PROBLEMS FOR ONCE AND ALL OR DOES A CUSTOMER FROM CHEVROLET JUST HAS TO SUFFER AND PUT UP WITH SUCH A POOR QUALITY?!*AK
NHTSA ODI #10058794
500 miles · Jan 25, 2004
Power Train
MY 2003 CHEVROLET CAVALIER HAS A PROBLEM OF STALLING ( ENGINE DIES)AT LOW SPEED WHEN CLUTCH IS DEPRESSED. OTHER OWNERS HAVE HAD THIS PROBLEM AS NOTED IN COMPLAINT SECTION OF THIS WEBSITE. WHEN THIS HAPPENS YOU MUST KEEP ENGINE REVS HIGH IN ORDER TO KEEP THIS FROM HAPPENING OVER AND OVER. THIS HAPPENED IN JUNE OF 2003 AND AGAIN J…
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MY 2003 CHEVROLET CAVALIER HAS A PROBLEM OF STALLING ( ENGINE DIES)AT LOW SPEED WHEN CLUTCH IS DEPRESSED. OTHER OWNERS HAVE HAD THIS PROBLEM AS NOTED IN COMPLAINT SECTION OF THIS WEBSITE. WHEN THIS HAPPENS YOU MUST KEEP ENGINE REVS HIGH IN ORDER TO KEEP THIS FROM HAPPENING OVER AND OVER. THIS HAPPENED IN JUNE OF 2003 AND AGAIN JAN. 15 2004. DEALER AND CHEVROLET CUSTOMER SERVICE SAY MORE OR LESS, SORRY ABOUT YOUR BAD LUCK. I AM NOT HAPPY ABOUT THIS AND I AM QUITE SURE I AM NOT THE ONLY ONE. THIS CONDITION COULD GET YOU KILLED. *LA
NHTSA ODI #10054836
300 miles · Jan 21, 2004
Electrical System
WITHIN A WEEK OF RECIEVING MY CAR IT BEGAN TO STALL WHEN COMMING TO A STOP OTHERWISE IT WOULD IDLE WRONG. IF IT DID NOT DIE IT WOULD IDLE HIGH. *AK
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 ↗
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.
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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