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
90,000 miles · Apr 6, 2011
Electrical System
I AM THE ORIGINAL OWNER OF A 2003 CHEVROLET CAVALIER. IT HAS 120000 MILES ON IT. A COUPLE OF YEARS AGO I NOTICED MY GAS GAGE SEEMED TO BE STUCK, THE CAR HAD APPROX 90000 MILES ON IT AT THE TIME. A COUPLE OF MONTHS LATER MY RPM GAUGE STARTED DOING THE SAME THING. ABOUT A YEAR AFTER THAT MY SPEEDOMETER STARTED TO ALSO GO HAYWI…
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I AM THE ORIGINAL OWNER OF A 2003 CHEVROLET CAVALIER. IT HAS 120000 MILES ON IT. A COUPLE OF YEARS AGO I NOTICED MY GAS GAGE SEEMED TO BE STUCK, THE CAR HAD APPROX 90000 MILES ON IT AT THE TIME. A COUPLE OF MONTHS LATER MY RPM GAUGE STARTED DOING THE SAME THING. ABOUT A YEAR AFTER THAT MY SPEEDOMETER STARTED TO ALSO GO HAYWIRE FOLLOWED BY MY OIL GAUGE. MY WHOLE INSTRUMENT CLUSTER NO LONGER WORKS. IT HAS NOT BEEN FIXED BECAUSE I CAN'T AFFORD IT AND IT HAS NOT BEEN RECALLED. BUT AFTER LOOKING AT HOW MANY CAVALIER HAVE HAD THIS SAME PROBLEM I BELIEVE IT SHOULD BE RECALLED. *TR
NHTSA ODI #10394434
167,000 miles · Mar 22, 2011
Air BagsCrashInjury
MVA OCCURRED WHILE SWERVING TO MISS A DEER. DRIVER UNABLE TO NEGOTIATE THE RIGHT HAND TURN RESULTING IN A HEAD ON COLLISION IN AN EMBANKMENT. CAR SKIDDED ACROSS THE ROAD OVER A DITCH APPX 3 FEET WIDE AND APXX 1-2 FEET DEEP, THEN HIT THE EMBANKMENT HEAD ON AT AN UNKNOWN SPEED. DRIVER STATED SHE WAS GOING APPX 40-50 MPH PRIOR TO …
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MVA OCCURRED WHILE SWERVING TO MISS A DEER. DRIVER UNABLE TO NEGOTIATE THE RIGHT HAND TURN RESULTING IN A HEAD ON COLLISION IN AN EMBANKMENT. CAR SKIDDED ACROSS THE ROAD OVER A DITCH APPX 3 FEET WIDE AND APXX 1-2 FEET DEEP, THEN HIT THE EMBANKMENT HEAD ON AT AN UNKNOWN SPEED. DRIVER STATED SHE WAS GOING APPX 40-50 MPH PRIOR TO SWERVING FOR THE DEER, SHE THINKS SHE MIGHT HAVE SLOWED DOWN TO APPX 30-40 MPH PRIOR TO HITTING THE EMBANKMENT. AFTER THE INITIAL IMPACT WITH THE EMBANKMENT THE CAR ROLLED APPX 1.5 - 2 TIMES LANDING ON THE DRIVER SIDE DOOR. THE AIR BAGS DID NOT DEPLOY, UNRESTRAINED DRIVER HIT THE WINDSHIELD CAUSING BRUISING, CONCUSSION, ABRASIONS, LACERATION TO THE SCALP. NO PASSENGERS NOTED TO BE IN THE VEHICLE OTHER THEN DRIVER. CAR IS TOTALED. DRIVER IS CURRENTLY OFF OF WORK DUE TO CLOSED HEAD INJURY AS ADVISED PER ER PHYSICIAN. *TR
NHTSA ODI #10392550
92,800 miles · Mar 21, 2011
Fuel System, Gasoline
THE CAR JUST WOULD NOT START ONE MORNING AFTER NO WARNINGS! I HAD IT TOWED TO THE SHOP AND WAS TOLD THE FUEL PUMP, FUEL FILTER AND SOME TYPE OF MODULE WOULD HAVE TO BE REPLACED, AT A COST OF $900.00!!! *TR
NHTSA ODI #10392339
95,000 miles · Mar 19, 2011
Fuel System, Gasoline
MY WIFE WAS PICKING OUR CHILDREN UP FROM SCHOOL. WHEN SHE PULLED OUT INTO THE FLOW OF TRAFFIC HER CAR DIED IN THE MIDDLE OF THE ROAD. THIS OF THE SECOND TIME THE FUEL PUMP HAS GONE OUT THE FIRST TIME WAS ABOUT 60K MILES THE CAR NOW HAS 95K AND I ALREADY HAVE TO REPLACE IT. I'VE READ ABOUT MANY OTHER PEOPLE HAVING THE SAME PROBLE…
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MY WIFE WAS PICKING OUR CHILDREN UP FROM SCHOOL. WHEN SHE PULLED OUT INTO THE FLOW OF TRAFFIC HER CAR DIED IN THE MIDDLE OF THE ROAD. THIS OF THE SECOND TIME THE FUEL PUMP HAS GONE OUT THE FIRST TIME WAS ABOUT 60K MILES THE CAR NOW HAS 95K AND I ALREADY HAVE TO REPLACE IT. I'VE READ ABOUT MANY OTHER PEOPLE HAVING THE SAME PROBLEM AND EVERYONE IS WONDERING WHY NO RECALL. *TR
NHTSA ODI #10392207
85,000 miles · Mar 7, 2011
Fuel System, Gasoline
WAS DRIVING VEHICLE AND WITH NO WARNING IT STALLED OUT. IT IS CURRENTLY AT THE GARAGE WITH AN ESTIMATE OF 700-900 TO REPLACE THE FUEL PUMP. I DO NOT HAVE THIS MONEY SO I AM NOW A SINGLE PARENT WITHOUT A VEHICLE FOR A PROBLEM THAT SHOULD HAVE BEEN RECALLED PREVIOUSLY. I THANK GOD MY CHILD WAS NOT IN THE VEHICLE. *TR
NHTSA ODI #10386759
78,000 miles · Feb 16, 2011
Fuel System, Gasoline
DRIVING DOWN THE HIGHWAY AT 70 MPH. THE CAR BEGAN TO SHUDDER AND LOSE ACCELERATION. I GOT OFF AT THE NEAREST EXIT AND AS I PASSED THROUGH THE EXIT INTERSECTION, THE ENGINE DIED. I COASTED INTO A GAS STATION, WHERE THE ENGINE WOULD TURN OVER AND THEN DIE RIGHT AWAY. AFTER 15 MINUTES IT NO LONGER TURNED OVER....THE TOW TRUCK MA…
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DRIVING DOWN THE HIGHWAY AT 70 MPH. THE CAR BEGAN TO SHUDDER AND LOSE ACCELERATION. I GOT OFF AT THE NEAREST EXIT AND AS I PASSED THROUGH THE EXIT INTERSECTION, THE ENGINE DIED. I COASTED INTO A GAS STATION, WHERE THE ENGINE WOULD TURN OVER AND THEN DIE RIGHT AWAY. AFTER 15 MINUTES IT NO LONGER TURNED OVER....THE TOW TRUCK MAN TRIED IT. TURNS OUT THE FUEL PUMP IS SHOT AND APPARENTLY THIS IS A COMMON PROBLEM FOR 03 CAVALIERS. THE CAR ONLY HAS 78,000 MILES ON IT. *TR
NHTSA ODI #10382870
50,000 miles · Feb 15, 2011
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT THE VEHICLE STALLED WITHOUT WARNING. THE FAILURE OCCURRED WHILE DRIVING OR AT A TRAFFIC LIGHT WITHOUT WARNING. THE CONTACT WAS ABLE TO RESTART THE VEHICLE WITHOUT INCIDENT WHENEVER THE FAILURE OCCURRED. THE MECHANIC REPLACED THE FUEL PUMP, BUT THE FAILURE OCC…
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TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT THE VEHICLE STALLED WITHOUT WARNING. THE FAILURE OCCURRED WHILE DRIVING OR AT A TRAFFIC LIGHT WITHOUT WARNING. THE CONTACT WAS ABLE TO RESTART THE VEHICLE WITHOUT INCIDENT WHENEVER THE FAILURE OCCURRED. THE MECHANIC REPLACED THE FUEL PUMP, BUT THE FAILURE OCCURRED AGAIN ALMOST ONE YEAR LATER. THE FAILURE MILEAGE WAS 50,000 AND THE CURRENT MILEAGE WAS 60,000. UPDATED 5/2/11 *CN UPDATED 05/13/11
NHTSA ODI #10382752
68,244 miles · Jan 28, 2011
Electrical System
TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT THE INSTRUMENT CLUSTER PANEL FAILED WHILE DRIVING 35 MPH. THE VEHICLE WAS TAKEN TO THE DEALER WHO STATED THAT THE PARTS NEEDED FOR REPAIRS WOULD TAKE TWO WEEKS TO BECOME AVAILABLE. THE MANUFACTURER WAS CONTACTED AND OFFERED NO ASSISTANCE. THE FAILURE MILEAGE…
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TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT THE INSTRUMENT CLUSTER PANEL FAILED WHILE DRIVING 35 MPH. THE VEHICLE WAS TAKEN TO THE DEALER WHO STATED THAT THE PARTS NEEDED FOR REPAIRS WOULD TAKE TWO WEEKS TO BECOME AVAILABLE. THE MANUFACTURER WAS CONTACTED AND OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS 68,244.
NHTSA ODI #10379419
60,000 miles · Jan 20, 2011
Fuel System, Gasoline
FUEL PUMP FAILURE RESULTING IN THE ENGINE DYING AND NOT BEING ABLE TO RESTART. THE CAR WAS RUNNING FINE WITH ABOUT A HALF TANK OF GAS WHEN THE ENGINE DIED IN TRAFFIC. I WAS ABLE TO SAFELY STOP THE CAR BUT NOT IN ALL CIRCUMSTANCES WOULD THAT BE POSSIBLE. THE CAR AS AROUND 60,000 MILES ON IT AND A COMPLETE FUEL PUMP FAILURE WHILE …
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FUEL PUMP FAILURE RESULTING IN THE ENGINE DYING AND NOT BEING ABLE TO RESTART. THE CAR WAS RUNNING FINE WITH ABOUT A HALF TANK OF GAS WHEN THE ENGINE DIED IN TRAFFIC. I WAS ABLE TO SAFELY STOP THE CAR BUT NOT IN ALL CIRCUMSTANCES WOULD THAT BE POSSIBLE. THE CAR AS AROUND 60,000 MILES ON IT AND A COMPLETE FUEL PUMP FAILURE WHILE IN OPERATION IS UNACCEPTABLE ON A VEHICLE UNDER TEN YEARS OLD WITH UNDER 100,000 MILES ON IT. I UNDERSTAND THAT THIS IS A COMMON PROBLEM. *TR
NHTSA ODI #10378084
70,000 miles · Jan 19, 2011
Electrical System
SPEEDOMETER REGISTERS OVER 120 MILES AND BEYOND EVEN WHEN STOPPED. *TR
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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