1. HIGH USE OF TRANSMISSION SHIFT CABLE LEADS TO SEPARATION AT THE TRANSMISSION END LINK. 2. ONCE THE SHIFT CABLE LINK WEARS OUT IT FALLS DOWN AND THE TRANSMISSION CAN NO LONGER BE SHIFTED THROUGH GEAR POSITIONS FROM WITHIN THE VEHICLE. A VEHICLE CAN BE LEFT STRANDED IN ANY GEAR, DRIVE, REVERSE, NEUTRAL, OR ANY OTHER POSITION…
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1. HIGH USE OF TRANSMISSION SHIFT CABLE LEADS TO SEPARATION AT THE TRANSMISSION END LINK. 2. ONCE THE SHIFT CABLE LINK WEARS OUT IT FALLS DOWN AND THE TRANSMISSION CAN NO LONGER BE SHIFTED THROUGH GEAR POSITIONS FROM WITHIN THE VEHICLE. A VEHICLE CAN BE LEFT STRANDED IN ANY GEAR, DRIVE, REVERSE, NEUTRAL, OR ANY OTHER POSITION. 3. A TEMPORARY FIX IS POSSIBLE WITH A ZIP TIE, BUT IS ONLY TEMPORARY DUE TO HEAT AND WEAR ON THE ZIP TIE. AN OE REPLACEMENT FOR THE SHIFT CABLE NEEDS TO BE INSTALLED. THIS IS A HIGH FAILURE ITEM LEADING TO STRANDED VEHICLES IN MANY DANGEROUS LOCATIONS AND NEEDS TO BE UPGRADED WITH A FAIL SAFE CONNECTION AT THE TRANSMISSION END. *TR
NHTSA ODI #10283087
87,000 miles · Feb 21, 2006
Engine And Engine CoolingPower Train
DT*: THE CONTACT STATED INTERMITTENTLY, THE VEHICLE STALLED WHILE DRIVING. THERE WERE NO WARNING LIGHTS WHEN THIS OCCURRED. THE VEHICLE WAS PUT IN NEUTRAL THEN RESTARTED. THE DEALERSHIP WAS UNABLE TO DUPLICATE THE PROBLEM. ALSO, THE CLUTCH FAILED ON THE VEHICLE TWICE. THE FIRST TIME OCCURRED WHILE PARKED AND THE DEALERSHIP…
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DT*: THE CONTACT STATED INTERMITTENTLY, THE VEHICLE STALLED WHILE DRIVING. THERE WERE NO WARNING LIGHTS WHEN THIS OCCURRED. THE VEHICLE WAS PUT IN NEUTRAL THEN RESTARTED. THE DEALERSHIP WAS UNABLE TO DUPLICATE THE PROBLEM. ALSO, THE CLUTCH FAILED ON THE VEHICLE TWICE. THE FIRST TIME OCCURRED WHILE PARKED AND THE DEALERSHIP REPLACED THE CLUTCH PIN. THE SECOND TIME, 3 MONTHS LATER, WHILE DRIVING THE CLUTCH WENT TO THE FLOOR. THE VEHICLE WAS TOWED TO A MECHANIC WHERE IT IS CURRENTLY BEING REPAIRED.
NHTSA ODI #10150782
Mileage unknown · Dec 1, 2004
Air BagsElectrical SystemEngine And Engine Cooling
NUMEROUS OF FAILURES;AIR BAG LIGHT CAME ON AND STAYED ON, CLUTCH STICKS TO FLOOR, CAR DOESN'T WANT TO START. *BF THE TURN SIGNALS AND LIGHTS HAD GONE OUT, IT WOULD TAKE A COUPLE OF ATTEMPTS TO START THE VEHICLE, THERE WERE TIMES WHERE THE VEHICLE WOULD START ON IT'S OWN WITHOUT THE TURN OF THE KEY, THE VEHICLE USED AN EXTREM…
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NUMEROUS OF FAILURES;AIR BAG LIGHT CAME ON AND STAYED ON, CLUTCH STICKS TO FLOOR, CAR DOESN'T WANT TO START. *BF THE TURN SIGNALS AND LIGHTS HAD GONE OUT, IT WOULD TAKE A COUPLE OF ATTEMPTS TO START THE VEHICLE, THERE WERE TIMES WHERE THE VEHICLE WOULD START ON IT'S OWN WITHOUT THE TURN OF THE KEY, THE VEHICLE USED AN EXTREME AMOUNT OF GAS, THE DASH WOULD RATTLE, THE ENGINE WOULD GROWL, THE DASH MADE A SOUND LIKE THE SPEAKER WAS BLOWN, THERE WAS A BURNING SMELL IN THE STEREO AND THERE WAS A THUMPING NOISE WHEN TURNING THE VEHICLE. (2003 PONTIAC SUNFIRE) *SC
NHTSA ODI #10109784
Mileage unknown · Aug 26, 2003
Power Train
WHILE APPLYING THE GEAR TO SHIFT AND WITHOUT PRIOR WARNING VEHICLE STARTED VIBRATING, AND THE TRANSMISSION LOCKED UP.*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 ↗
NHTSA investigations
2
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 Pontiac Sunfire Problems, Complaints & Recalls | Skip That Year
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