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
200 miles · Nov 14, 2003
Engine And Engine Cooling
CAR STALLS. THIS HAS BEEN REPORTED TO THE DEALER. CAR HAS BEEN TO THE DEALER ON 2 OCCASIONS FOR THIS ISSUE. ALWAYS GET RESPONSE, "CANNOT DUPLICATE THE ISSUE." JUST PURCHASED 2003 CAVALIER IN JULY OF THIS YEAR. VEHICLE ONLY HAS 7000 MILES ON IT. THIS BEGAN IN AUGUST. HAVE BEEN REPORTING THESE INCIDENTS TO THE DEALER EVER S…
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CAR STALLS. THIS HAS BEEN REPORTED TO THE DEALER. CAR HAS BEEN TO THE DEALER ON 2 OCCASIONS FOR THIS ISSUE. ALWAYS GET RESPONSE, "CANNOT DUPLICATE THE ISSUE." JUST PURCHASED 2003 CAVALIER IN JULY OF THIS YEAR. VEHICLE ONLY HAS 7000 MILES ON IT. THIS BEGAN IN AUGUST. HAVE BEEN REPORTING THESE INCIDENTS TO THE DEALER EVER SINCE. *LA
NHTSA ODI #10046940
457 miles · Nov 12, 2003
Seat BeltsInjury
CONSUMER FELT THAT SEAT BELT WAIS DEFECTIVE. THE SEAT BELT CUT INTO THE CONSUMER'S NECK AND IT IS WAS TOO HIGH UP ON HER NECK. ALSO, THE LAP BELT WASS TOO TIGHT AROUND THE CONSUMER'SWAIST. THE DEALER TRIED TO PUT EXTENDERS ON THE BELTS, BUT TO NO AVAIL. THE CONSUMER STILL FEELS UNCOMFORTABLE USING THE SEAT BELTS. *AK …
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CONSUMER FELT THAT SEAT BELT WAIS DEFECTIVE. THE SEAT BELT CUT INTO THE CONSUMER'S NECK AND IT IS WAS TOO HIGH UP ON HER NECK. ALSO, THE LAP BELT WASS TOO TIGHT AROUND THE CONSUMER'SWAIST. THE DEALER TRIED TO PUT EXTENDERS ON THE BELTS, BUT TO NO AVAIL. THE CONSUMER STILL FEELS UNCOMFORTABLE USING THE SEAT BELTS. *AK CONSUMER HAD TWO ADDITIONAL CONCERNS. FIRST, THE SEAT BELT GETS TANGLES EVERY TIME IT FASTENED AND IS UNCOMFORTABLE. SECONDLY, THE VEHICLE HAD 162 MILES AT PURCHASE AND SHE WAS TOLD THIS WAS NOT UNUSUAL. *JB
NHTSA ODI #10044322
32,000 miles · Nov 11, 2003
Service Brakes, Hydraulic
GRINDING NOISE IN THE BRAKING SYSTEM WHEN BRAKES ARE APPLIED. HAVE HAD THE CAR BACK TO THE DEALER FOR SERVICE TWICE. THE SECOND TIME SERVICE MANAGER STATED THAT GM WAS WELL AWARE OF THE PROBLEM, THAT ALL CAVALIERS HAVE IT AND THERE IS NOTHING THEY CAN DO ABOUT IT. SERVICE MANAGER STATED THAT IT WAS CAUSED BY "TRAVEL" IN THE CA…
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GRINDING NOISE IN THE BRAKING SYSTEM WHEN BRAKES ARE APPLIED. HAVE HAD THE CAR BACK TO THE DEALER FOR SERVICE TWICE. THE SECOND TIME SERVICE MANAGER STATED THAT GM WAS WELL AWARE OF THE PROBLEM, THAT ALL CAVALIERS HAVE IT AND THERE IS NOTHING THEY CAN DO ABOUT IT. SERVICE MANAGER STATED THAT IT WAS CAUSED BY "TRAVEL" IN THE CALIPERS.*AK
NHTSA ODI #10045935
Mileage unknown · Nov 6, 2003
Visibility
DRIVER'S SIDE REARVIEW MIRROR VIBRATES, ESPECIALLY WHEN DRIVING IN WINDY CONDITIONS AND/OR ON FREEWAY. SOMETIMES IT IS BAD ENOUGH WHERE DRIVER CAN'T SEE CARS BEHIND HIM. DEALER REPLACED MIRROR WHEN CAR WAS A COUPLE WEEKS OLD. NO DIFFERENCE. INFORMED DEALER ABOUT TSB 03-08-64-011 REGARDING THE INSULATOR AND TORQUE NUTS FOR T…
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DRIVER'S SIDE REARVIEW MIRROR VIBRATES, ESPECIALLY WHEN DRIVING IN WINDY CONDITIONS AND/OR ON FREEWAY. SOMETIMES IT IS BAD ENOUGH WHERE DRIVER CAN'T SEE CARS BEHIND HIM. DEALER REPLACED MIRROR WHEN CAR WAS A COUPLE WEEKS OLD. NO DIFFERENCE. INFORMED DEALER ABOUT TSB 03-08-64-011 REGARDING THE INSULATOR AND TORQUE NUTS FOR THE MIRROR. DEALER PERFORMED REPAIRS ACCORDING TO TSB. OTHER MODELS EXHIBIT SAME CONDITION.*AK
NHTSA ODI #10045633
2,000 miles · Nov 5, 2003
Engine And Engine Cooling
VEHICLE STALLED WHILE DRIVING 65 MPH ON THE HIGHWAY. THE CAUSE OF THE PROBLEM HAD NOT BEEN DETERMINED. *AK
NHTSA ODI #10046420
Mileage unknown · Nov 5, 2003
Wheels
WHILE DRIVING, THE HUB KEPT FALLING OFF. THE VEHICLE WAS TAKEN TO THE DEALER 5 TIMES. THE DEALER TIGHTENED AND REPLACED THE PART BY USING SILICONE GLUE, THREADING THE LOCKER ON THE HUBS. THE PROBLEM REMAINED THE SAME AND HAD NOT BEEN CORRECTED. *AK THE PROBLEM STARTED A WEEK AFTER THE VEHICLE WAS PURCHASED. (THREADING TH…
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WHILE DRIVING, THE HUB KEPT FALLING OFF. THE VEHICLE WAS TAKEN TO THE DEALER 5 TIMES. THE DEALER TIGHTENED AND REPLACED THE PART BY USING SILICONE GLUE, THREADING THE LOCKER ON THE HUBS. THE PROBLEM REMAINED THE SAME AND HAD NOT BEEN CORRECTED. *AK THE PROBLEM STARTED A WEEK AFTER THE VEHICLE WAS PURCHASED. (THREADING THE LOCKER WHICH WAS STATED ON THE PACKAGE WAS "NOT FOR USE ON PLASTIC") *SCC *JB
NHTSA ODI #10042583
12,603 miles · Nov 5, 2003
Air BagsSeat BeltsCrashInjury
WHILE DRIVING APPROXIMATELY 20 MPH CONSUMER'S VEHICLE REAR ENDED ANOTHER VEHICLE, AND THE FRONT AIR BAGS DID NOT DEPLOY. DRIVER'S CHEST HIT THE STEERING WHEEL, CAUSING MUSCLE SPASMS FROM THE NECK DOWN. *AK THE SEAT BELTS ALSO FAILED TO LOCK. *PH *NLM
NHTSA ODI #10042348
22,000 miles · Nov 5, 2003
Fuel System, Gasoline
CONSUMER STATES THAT AT 60 MPH VEHICLE SHUTS DOWN. THEN VEHICLE WOULD RESTART AFTER DRIVER SAT AND WAITED A WHILE.*AK THIS OCCURRED TWICE. THE DEALER REPLACED A FAULTY FUEL PUMP. *PH *NLM
NHTSA ODI #10042333
5 miles · Oct 30, 2003
Wheels
WHILE APPROACHING THE VEHICLE CONSUMER NOTICED A FLAT TIRE. CONSUMER TOOK VEHICLE TO A DISCOUNT TIRE SHOP. AT THE TIRE SHOP TECHNICIAN INFORMED CONSUMER THAT THE TIRE WAS FINE, BUT THE WHEEL RIM BROKE IN TWO PIECES. THE MANUFACTURER AND THE DEALER WERE INFORMED OF THE PROBLEM.*AK
NHTSA ODI #10046101
Mileage unknown · Oct 30, 2003
Tires
ON SEPT 23, 2003 I CALLED THE SERVICE DEPARTMENT AT SHOWCASE CHEVROLET WHERE I BOUGHT THE CAVALIER. TALKED TO A SERVICE ADVISOR ABOUT THE PROBLEM WITH MY VEHICLE. THE CAR WAS VERY HARD TO HANDLE ON GROOVE ROADS. IT FELT LIKE THE BACK-END WAS GOING ONE WAY AND THE FRONT THE OTHER. HE SAID HE WOULD LOOK AT IT, HE STATED THAT T…
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ON SEPT 23, 2003 I CALLED THE SERVICE DEPARTMENT AT SHOWCASE CHEVROLET WHERE I BOUGHT THE CAVALIER. TALKED TO A SERVICE ADVISOR ABOUT THE PROBLEM WITH MY VEHICLE. THE CAR WAS VERY HARD TO HANDLE ON GROOVE ROADS. IT FELT LIKE THE BACK-END WAS GOING ONE WAY AND THE FRONT THE OTHER. HE SAID HE WOULD LOOK AT IT, HE STATED THAT THEY PUT MORE AIR IN THE TIRES AND THAT SHOULD DO IT. THE NEXT DAY I CALLED AND ASK TO SPEAK TO THE SERVICE MANAGER AS THE VEHICLE WAS WORSE. TROY (SVC. MGR.) SAID HE WOULD DRIVE WITH ME. WE TOOK THE VEHICLE DOWN THE ROAD AND IT SWERVED AND TROY STATED TO ME HE FELT THE PROBLEM AND WAS HOLDING ON. HE TOLD ME TO TAKE IT BACK AS HE IS NOT SAFE IN IT. HE STATED THAT THE VEHICLE WAS UNSAFE TO DRIVE AND THAT HE FEELS THAT IT IS THE TIE RODS. HE TOOK THE VEHICLE BACK TO THE SHOP AND READJUSTED THE TIE RODS, REBALANCED TIRES, AND STATED THAT HE DROVE THE OTHER CAVALIERS AND ALL WITH 14 INCH TIRES HAD THE SAME PROBLEM. I ASKED HIM WHAT HE COULD DO ABOUT THIS AND HE STATED THAT THE VEHICLES WITH 15 INCH TIRES DIDN'T DO THAT AND WE COULD BUY RIMS AND TIRES AND HE FEELS THAT SHOULD SOLVE THE PROBLEM. ON THE THIRD TRIP TO THE SERVICE DEPT. HE SAID HE COULDN'T HELP WITH THE TIRES AS THEY DIDN'T HAVE ANY 15 INCH RIMS AROUND AND I WOULD HAVE TO PAY FOR THEM. HE STATED HE COULD NOT WARRANTY THEM OUT AS IT IS AN UPGRADE IN THE VEHICLE. I HAVE NO WAY OF KNOWING THAT PUTTING 15 INCH TIRES ON THIS VEHICLE WILL SOLVE THE PROBLEM. I HAVE CONTACTED GM AND THEY STATE THE VEHICLE IS UP TO THEIR SPECIFICATIONS FOR THAT CAR AND THEY WILL NOT DO ANYTHING TO THE VEHICLE OR VEHICLE WITH 14 INCH TIRES. IT WAS NOT BROUGHT UP AS AN OPTION TO ME WHEN I BOUGHT THE VEHICLE AS THE GM CUSTOMER SERVICE REPRESENTATIVE STATED. HOW CAN THEY LET THESE CARS STAY ON THE ROAD WITH A PROBLEM CONTROLLING THEM ON GROOVE ROADS? THE SERVICE MANAGER STATED THAT HE WOULD NOT DRIVE THIS VEHICLE ON THE ROAD DURING RAIN OR SNOW AS YOU COULD EASILY LOOSE CONTROLS IN THE GROOVES. *LA
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.
2003 Chevrolet Cavalier Problems, Complaints & Recalls | Skip That Year
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