2002 Chevrolet Camaro Owner Complaints

2002 CHEVROLET CAMARO. CONSUMER WRITES IN REGARDS TO A DESIGN DEFECT. *LD THE CONSUMER STATED THERE WAS A RECURRING PROBLEM WITH THE SAIL ROOF PANEL BUBBLING THROUGH THE BLACK PAINT OF THE VEHICLE. THE CONSUMER WAS ADVISED, BY THE DEALER, THAT THE ADHESIVE WAS CAUSING THE FAILURE. THE SAIL ROOF IS NO LONGER BEING MANUFACTURED. THE ONLY WAY TO REPAIR THE PART WOULD BE TO FIND A REPLACEMENT AT A JUNK YARD. THE CONSUMER STATED THAT WAS UNACCEPTABLE. *JS

NHTSA ID

11354677

Incident

Sep 15, 2020

TL* THE CONTACT OWNS A 2002 CHEVROLET CAMARO. THE CONTACT STATED THAT THE DRIVER SIDE POWER WINDOW BECAME INOPERABLE. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE WINDOW REGULATOR FAILED AND NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED; HOWEVER, THE FAILURE RECURRED NUMEROUS TIMES. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VIN WAS INVALID. THE FAILURE MILEAGE WAS UNKNOWN. ..UPDATED 12/20/16 *BF *TR

NHTSA ID

10907564

Incident

Sep 19, 2012

Mileage

19,373 mi

TL* THE CONTACT OWNS A 2002 CHEVROLET CAMARO. WHILE DRIVING APPROXIMATELY 35 MPH, THE STEERING BECAME DIFFICULT TO TURN WITHOUT WARNING. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE AND VIN WERE UNAVAILABLE.

NHTSA ID

10886079

Incident

Jul 5, 2016

TYPICALLY IN THE AFTERNOON ON WARM / HOT DAYS AND AFTER THE CAR HAS SAT ALL DAY OUTSIDE, I'LL GO TO START IT, PUT THE KEY INTO START POSITION AND THE STARTER WILL NOT ENGAGE. ALL ELSE SEEMS TO BE FUNCTIONING CORRECTLY. THE FUEL AND TEMP GAUGES GO BACK TO 0 POSITION, VOLTAGE DROPS BUT NOT BY MUCH. I HAVE HAD TO SWITCH TO THE START POSITION AS MUCH AS 75 TIMES BEFORE THE STARTER ENGAGES. WHEN IT DOES ENGAGE IT IS TURNS OVER STRONGLY. THIS ISN'T A BATTERY PROBLEM. I CAN'T FIND A PATTERN TO TIE TO WHEN THIS HAPPENS EXCEPT IT IS MOSTLY IN THE AFTERNOON ON WARM / HOT DAYS AND AFTER THE CAR HAS SAT ALL DAY OUTSIDE. *TR

NHTSA ID

10627747

Incident

Jul 1, 2013

TL* THE CONTACT OWNS A 2002 CHEVROLET CAMARO. THE CONTACT STATED THAT WHILE DRIVING AT 60 MPH, THE ENGINE STALLED. THE FAILURE RECURRED SEVERAL TIMES. THE VEHICLE WAS TOWED TO THE DEALERS WHO WAS NOT ABLE TO DUPLICATE THE PROBLEM. THE VEHICLE HAD NOT BEEN REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 85,000. UPDATED 09/22/2014*LJ UPDATED 2/23/2015 *JS THE CONSUMER STATED THE FUEL PUMP WAS REPLACED. THE VEHICLE SHUT OFF TWICE ON THE FREEWAY. UPDATED 2/23/2015 *JS

NHTSA ID

10615109

Incident

Jul 17, 2014

Mileage

85,000 mi

TL* THE CONTACT OWNS 2002 CHEVROLET CAMARO. THE CONTACT STATED THAT THE PASSENGER SIDE TURNING SIGNAL FAILED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSE THAT THE RIGHT SIGNAL COMPARTMENT AREA RETAINED WATER AND CAUSED THE BULB TO FAIL. THE BULB COMPARTMENT WAS CUT FOR THE WATER TO LEAK AND THE BULB WAS REPLACED, HOWEVER THE FAILURE WAS NOT CORRECTED. THE RIGHT DIRECTIONAL BULB CONTINUED TO FAIL. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 67,463 AND THE CURRENT MILEAGE WAS 73,000.

NHTSA ID

10473196

Incident

Dec 1, 2011

Mileage

67,463 mi

DRIVING HOME FROM WORK AT 40 MPH AND SUDDENLY ALL THE RED WARNING LIGHTS APPEAR AS I LOSE POWER-STEERING, ALTERNATOR NOT CHARGING, AND MY ENGINE TEMPERATURE RISES TO 300 DEGREES F. I PULLED OVER TO SIDE OF THE ROAD IMMEDIATELY TO CHECK UNDER THE HOOD. THE PRESSED-ON POWER STEERING PULLEY HAD COME COMPLETELY OFF THE POWER STEERING PUMP AND CONSEQUENTLY CAUSING THE SERPENTINE BELT TO FLY OFF. I RARELY DRIVE THIS CARE AND IT HAS ONLY 15,000 MILES. SO MUCH GENERAL MOTORS QUALITY. *JS

NHTSA ID

10463918

Incident

Jun 25, 2012

Mileage

15,000 mi

I HAVE A 2002 CHEVY CAMARO THAT IS EXPERIENCING A SECURITY LIGHT ISSUE AND HAVE BEEN READING UP ON IT ONLINE....THIS IS SUCH A HAZARD AND A DANGER TO OTHER DRIVERS I CANT BELEIVE IT ISNT UNDER INVESTIGATION, GIVEN THAT THE NUMBERS OF COMPLAINTS ARE OUTRAGEOUS! THE OTHER THING IS THE MONOPLY THAT GM HAS ON THIS PROBLEM, THEY ARE THE ONLY ONES WHO CAN FIX IT, NOT YOUR FAVORITE HOME TOWN MECHANIC, BUT GM ONLY. THE TESTING EQUIPMENT USED TO DIAGNOSE THIS IS ONLY SOLD TO THEM! AND LET ME TELL U SOMETHING, THEY CHARGE OUT THE YINGER FOR THIS, COST OF CYLINDER 30.00 THEY CHARGE YOU 600.00...BCM MODULE...COST 130 AND THEY CHARGE YOU 800. THIS IS A ENDANGERMENT IN THE FACT THAT YOUR CAR..UMMM SAY GOING THE SPEED LIMIT ON THE HIGHWAY OF SAY 65...AND ALL OF A SUDDEN MY CAR DECIDES SOMONE IS STEALING IT....AND CUTS OFF THE GAS SUPPLY....WELL U CAN BET THERE IS GOING TO BE A PILE UP OF CRASHED CARS AND DEAD PEOPLE. THIS IS RIDICILIOUS AND THIS IS AMERICA AND THEY SHOULDNT HAVE A MONOPLY ON THIS...ALOT OF PEOPLE CANT AFFORD THIS DEFECT IN GM CARS SO THEY HAVE TO RISK MINE AND THEIR LIVES.....YOU NEED TO TAKE ACTION ON THIS AND HAVE GM RECALL THIS OR JUST GIVE CUSTOMERS THE OPTION OF THEM INSTALLING SOME KIND OF BYPASS OF THEY SYSTEM. ITS NOT ONLY OLDER CARS BUT NEW CARS TOO!!! *TR

NHTSA ID

10394010

Incident

Apr 2, 2011

Mileage

78,000 mi

2002 CHEVROLET CAMARO SS. CONSUMER STATES ENGINE FAILURE DUE TO WIRING HARNESS PLACEMENT. *TGW ACCORDING TO THE DEALERSHIP, THE NUMBER 7 CYLINDER MAY HAVE PASSED COMPRESSED LIQUID, MOST LIKELY FUEL THAT CAUSED THE PISTON AND ROD TO BE DAMAGED. IT CAUSED DAMAGE TO THE CYLINDER WALL WHICH REQUIRED REPLACEMENT OF THE ENGINE. THE TECHNICIAN ALSO INDICATED THAT THE NUMBER 8 CYLINDER WAS DAMAGED. THE DEALER STATED THE CAUSE FOR THE FUEL INJECTORS REMAINING IN THE OPEN POSITION WAS THE WIRING CONTROLLING THE FUEL INJECTORS WAS CHAFED AND MAKING CONTACT WITH THE BULKHEAD WHICH GROUNDED THE WIRING. THE CONSUMER STATED ONE DAY HE STARTED THE VEHICLE AND WHITE SMOKE EMITTED FROM THE EXHAUST, HE SHUT THE VEHICLE OFF AND LET IT SIT IN THE DRIVEWAY. THE CONSUMER STATED THE DISTANCE OF THE WIRING FROM THE BULKHEAD IS LESS THAN 1/4 OF AN INCH, THE PCM CAN BE MADE TO MOVE JUST UNDER 1/2 INCH WHICH WOULD BE ENOUGH DISTANCE FOR THE WIRES TO MAKE CONTACT WITH THE BULKHEAD. IT WOULD INDICATE THAT OVER TIME, VIBRATION FROM DRIVING CONDITIONS WOULD CAUSE THE PCM TO MOVE BACK AND FORTH WHICH STRONGLY SUGGEST A FLAW IN THE POSITIONING OF THE PCM. THERE WAS EVIDENCE TO SUGGEST THAT AN OUTSIDE SOURCE CAUSED THE WIRING TO CHAFE, SUCH AS RODENTS NESTING IN THE ENGINE COMPARTMENT. *JB

NHTSA ID

10319828

Incident

Sep 1, 2008

MY 2002 GM CHEVROLET CAMARO'S ABS BRAKE SYSTEM HAS FAILED.THERE WERE NO INCIDENTS THAT LED UP TO THE FAILURE OF THE COMPONENT. AS TO DATE 03/02/2010 MY ABS BRAKING SYSTEM IS INOPERABLE,I HAVE NO ABS. ONLY A WARNING LIGHT TELLING ME I HAVE NO ABS. THE FAILURE OCCURRED APPROX. 11/2 YEARS AGO,AND SINCE IT WAS NOT UNDER WARRANTY GM WILL NOT FIX THIS PROBLEM.AGAIN I BELIEVE THAT GM KNOWS OF THIS FAILURE IN THEIR SYSTEMS(ABS..ANTI-LOCK BRAKING SYSTEM)THE COST TO REPAIR OR REPLACE THIS ABS COMPONENTS IS APPRX.$2,500.00. MY INQUIRES WITH OTHER GM OWNERS OF OTHER MODELS IE;CORVETTE STATE THE SAME PROBLEMS AS THE CAMAROS. FAILURE OF THIS COMPONENTS IS VERY CRITICAL FOR SAFETY IN PREVENTING WHEELS FROM LOCKING UP AND CAUSING A SKID LEADING TO A VERY DANGEROUS ACCIDENT.(THE MAIN REASON CONSUMERS WANT ANTI-LOCK BRAKES!) *TR

NHTSA ID

10315817

Incident

Jun 11, 2008

Mileage

55,000 mi

MY COMPLAINT IS WITH A GM PRODUCT..A 2002 CHEVROLET CAMARO. NOT LONG AFTER PURCHASE (APPRX) LESS THAN A FEW MONTHS OF TAKING POSSESSION OF MY "NEW" VEHICLE THE DRIVERS SIDE WINDOW REGULATOR(POWER ASSISTED ) WAS HAVING PROBLEMS...THE REGULATOR WOULD STICK IN ANY POSITION UP/DOWN AND WOULD NOT OPERATE CORRECTLY . THE VEHICLE WAS UNDER WARRANTY AND WAS REPAIRED..THE REGULATOR ON THE PASSENGER SIDE THEN WENT OUT THE SAME WAY NOT LONG AFTER...AGAIN IT WAS REPAIRED.THIS PROBLEM HAS RE-OCCURRED SEVERAL TIMES SINCE 2002 TO THE PRESENT DATE AS OF 03/02/2010.I HAVE SPOKEN TO MANY CAMARO OWNERS AND THE RESPONSE IS EXACTLY THE SAME...WE ALL KNOW THAT OUR VEHICLE (CAMAROS) DO "THAT" . FIRST OF ALL THE CARS ARE NOW OUT OF WARRANTY AND THE FINANCIAL RESPONSIBILITY FALLS ON US ! THESE REPAIRS CAN EXCEED $500.00 DOLLARS. THERE IS NO DOUBT GM KNOWS OF THIS. I HAVE SPOKEN TO MANY OTHER CAMARO OWNERS AND ALL SAY THAT AN AFTERMARKET WINDOW REGULATOR SOLVED THEIR PROBLEM,ITS OBVIOUSLY DEFECTIVE WINDOW REGULATORS PERMIATED THERE STOCK AND GM REPLACED THEM WITH THE SAME DEFECTIVE PARTS. THESE PROBLEMS OCCURRED WITHOUT INCIDENT IE; ACCIDENTS,MISUSE ETC. FAILURE OF THESE COMPONENTS ARE VERY DANGEROUS, IF A DRIVER BECOMES TRAPPED INSIDE HIS/HER VEHICLE AND CANNOT EXIT THROUGH THE DOOR NORMALLY AND HAS TO DEPEND ON THE WINDOW AS AN EXIT THEY WILL BECOME TRAPPED INSIDE THAT VEHICLE AND COULD BE SERIOUSLY INJURED OR KILLED. NOT BEING ABLE TO ROLL THE WINDOWS UP OR DOWN WHEN NEEDED CAN BE VERY DANGEROUS (IE. FLOODS,FIRE,,SUBMERGED VEHICLE OR ASSAILANT.) *TR

NHTSA ID

10315805

Incident

Mar 10, 2002

Mileage

800 mi

TL*THE CONTACT OWNS A 2002 CHEVROLET CAMARO. THE CONTACT STATED THAT THE CONTROL BOX IN THE ENGINE, LOCATED NEAR THE FIREWALL, CAUSED THE FUEL INJECTORS TO POUR FUEL INTO THE ENGINE. AS A RESULT, THE ENGINE WAS RUINED. WHEN THE VEHICLE WAS STARTED, WHITE SMOKE APPEARED FROM THE EXHAUST. THE VEHICLE WAS TOWED TO THE DEALER, BUT THEY WENT OUT OF BUSINESS. THE VEHICLE WAS TOWED TO ANOTHER DEALER AND THEY REPLACED THE ENTIRE ENGINE. THE MANUFACTURER OFFERED HIM A 10% DISCOUNT AND THE CONTACT PAID $6,200 FOR THE REPAIR. THE CONTACT HAS A PHOTO OF WHERE THE BOX WAS LOCATED IN THE ENGINE, WHICH HE FELT WAS TOO CLOSE TO THE FIREWALL AND THE INITIAL CAUSE OF THE FAILURE. THE CURRENT AND FAILURE MILEAGES WERE APPROXIMATELY 44,000. UPDATED 1/26/09 *CN THE CONSUMER WAS THE NUMBER 7 CYLINDER MAY HAVE COMPRESSED LIQUID, MOST LIKELY FUEL THAT CAUSED THE PISTON AND ROD TO BE DAMAGED. IT CAUSED DAMAGED TO THE CYLINDER WALL WHICH REQUIRED THE REPLACEMENT OF THE ENGINE. THE CONSUMER WAS THEN TOLD THE FUEL INJECTORS WERE IN THE OPEN POSITION BECAUSE THE WIRING CONTROLLING THE FUEL INJECTORS WAS CHAFED AND MAKING CONTACT WITH THE BULKHEAD WHICH GROUNDED THE WIRING. UPDATED 01/27/09. *JB

NHTSA ID

10254101

Incident

Sep 1, 2008

Mileage

44,000 mi

FAULTY VALVE STEMS (LIKELY FROM THE CHINA RECALL) ON 2 GOODYEAR TIRES SO FAR ON MY CAR THAT CRACKED PREMATURELY. *TR

NHTSA ID

10232620

Incident

Jun 10, 2008

I HAVE NOTICED BUBBLING IN THE PAINT AROUND THE EDGES OF THE ROOF AND SAIL PANEL. I WAS TOLD THIS IS CAUSED BY A DEFECTIVE GLUE USED BY GM WHICH CAUSES THE PAINT TO DELAMINATE AND CORRODE. I TRIED TO CONTACT TWO DEALERSHIPS AND CHEVROLET CUSTOMER SERVICE BUT WAS DENIED EACH TIME. I BELIEVE THIS PROBLEM SHOULD BE COVERED UNDER THE 6YR/100,000 MILE PAINT WARRANTY. *TR

NHTSA ID

10207320

Incident

Oct 1, 2007

FRONT LEFT TURN SIGNAL/PARKING LIGHT KEEPS BURNING OUT. BOTH SIDES HAVE BEEN REPLACED WITH NEW SOCKETS COSTING AROUND $400.00, RIGHT AFTER THE WARRANTY EXPIRED. SINCE THEN THE LEFT SIDE HAS GONE OUT 3 MORE TIMES IN THE LAST YEAR COSTING $45.00 EACH TIME. IT IS IMPOSSBLE TO REACH THE BULB TO REPLACE IT YOURSELF. DEALER INSISTS THAT THE PARKING LENS WAS CRACKED CAUSING MOISTURE TO ENTER THE SOCKET. WHEN INSEPCTING THE VEHICLE, THERE IS NO CRACK.. NOW THEY SAY ITS THE SEAL AROUND THE PARKING LENS. I JUST REPLACED ANOTHER BURNT OUT BULB 6 WEEKS AGO AND IT HAPPENED AGAIN. IT ALSO HAS NOT RAINED TO CAUSE ANY MOISTURE IN THE LAST 6 WEEKS.

NHTSA ID

10206326

Incident

Oct 19, 2007

Mileage

32,000 mi

TL* THE CONTACT OWNS A 2002 CHEVROLET CAMARO. THE LEFT TURN SIGNAL LIGHT BURNED OUT AND MELTED THE WIRES. BOTH OF THE BLINKERS BURNED OUT ONE YEAR AGO AND THE DEALER REPLACED BOTH SOCKETS. THE CURRENT MILEAGE IS 76,000, AND FAILURE MILEAGE WAS 70,000. *AK

NHTSA ID

10189357

Incident

May 1, 2007

Mileage

70,000 mi

051406 DRIVING 35 MPH WHEN CHECK ENGINE LIGHT CAME ON WHEN CAR LOST ALL ACCELERATION . CAR WAS GOING DOWNHILL AND I BARELY MANAGED TO BRAKE AND STEER IT CLEAR INTO A LOT. TOWED TO DEALER. 49,000 MILES. FUEL PUMP NEEDS REPLACEMENT WHICH I FOUND WAS WAY TOO SOON. COST $1300. COMPLAINT IS TOO SOON FOR A REPLACEMENT AND MORE IMPORTANT WAS THE HEAVY NON RESPONDING STEERING AND NON RESPONDING BRAKING. VERY VERY LUCKY OTHER CARS WERE CLEAR. *NM

NHTSA ID

10158883

Incident

May 14, 2006

Mileage

47,861 mi

DT*: THE CONTACT STATED WHILE DRIVING AT VARIOUS SPEEDS AND APPLYING THE BRAKES THE FRONT END VIBRATES. WHEN THE PROBLEM FIRST OCCURRED AT 12,000 MILES THE DEALERSHIP RESURFACED THE BRAKE ROTORS. THE PROBLEM REOCCURRED AT 19,000 MILES AND AGAIN THE DEALER RESURFACED THE ROTORS. WHILE THE VEHICLE WAS AT THE DEALERSHIP FOR THE BRAKE PADS, IT WAS DETERMINED THE BRAKE ROTORS NEED TO BE REPLACED. THE BRAKE ROTORS WERE NOT REPLACED.

NHTSA ID

10152619

Incident

Mar 9, 2006

Mileage

46,000 mi

I HAVE A 2002 CHEVROLET CAMARO I PURCHASED IN OCTOBER OF 2004. MYSELF AND A FRIEND WERE ON OUR WAY TO WORK @ 6:15 AM WHEN WE WERE STRUCK HEAD ON BY A LARGE SUV. WE WERE RUNNING 45 MPH (HEAD ON" AND DRIVER NOR PASSENGER AIR BAGS DEPLOYED LEAVING MY PASSENGER"BEST FRIEND" WITH A LARGE BRUISE ON THE RIGHT SIDE OF HER BRAIN WHICH CAUSES TERRIBLE HEADACHES FOR HER, AND MYSELF WITH CONFLICTING BACK AND NECK PROBLEMS HAD THE AIRBAGS WENT OFF THEY WOULD HAVE AT LEAST KEPT US FROM JAMMING OUR BODIES AT FULL FORCE FORWARD INTO THE WINDSHIELD AND MYSELF THE STEERING WHEEL. THIS ACCIDENT DID $7000.00 WORTH OF DAMAGE TO THE FRONT OF THE CAMARO AND MESSED UP OUR LIVES FOREVER. INSTEAD OF TOTALING THE CAR LIKE IT SHOULD HAVE BEEN IT WAS FIXED AND IT IS STILL DEFECTIVE THE INSURANCE COMPANY WHICH DID NOT DO THERE JOB RIGHT IN EXAMINING THE CAR THOROUGHLY FOR THE EXTENT OF DAMAGE IT HAD, ALL THEY DID WAS LOOK AT THE CAR TAKE ONE PICTURE ESTIMATED THE COST AT $3500.00 LESS THAN WHAT IT ENDED UP COSTING TO REPAIR, THEY NEVER LOOKED UNDER THE HOOD NOR THE FRONT END TO SEE THAT THE FRONT END ON THE DRIVER SIDE WAS COMPLETELY DESTROYED THE TIRE WAS FALLING OFF AND NOT ATTACHED TO ANYTHING COMPLETELY DESTROYED AND STILL NO AIR BAGS. HE WOULD NOT EVEN AUTHORIZE THE BODY SHOP TO CHECK THE AIR BAGS NOR CENSORS. I HAVE A SON THAT HAS TO RIDE IN THIS DEFECTIVE CAR AND THAT SCARES ME TO DEATH. WE WERE ALMOST KILLED!! WE STILL CANT WORK DUE TO THE EXTENT OF OUR INJURIES. I PAY $400.00 A MONTH FOR A CAR I ONCE LOVED MY FIRST NICE CAR WHICH IS NOW A CAR I HATE AND AM SCARED OF. I CANT GET A DIFFERENT ONE I HAVE NO INCOME. I FEEL GM SHOULD STEP UP HELP OUT AND TAKE RESPONSIBILITY FOR THIS MISTAKE. IF NOT WE MAY HAVE TO TAKE FURTHER ACTION. *JB

NHTSA ID

10151761

Incident

Jul 6, 2005

Mileage

51,855 mi

DURING THE CALIFORNIA RAINS OF 2005, MY CAMARO'S T-TOP ROOF LEAKED SO MUCH THAT THERE WAS 1 1/2" OF WATER IN THE BOTTOM OF THE CAR. THE DEALER REMOVED THE INTERIOR AND ALLOWED IT TO DRY, BUT THE MANUFACTURER REFUSED TO COVER THE REPAIRS AS A WARRANTY EVEN THOUGH THE CAR WAS ONLY 2 YEARS OLD AND I OWNED AN EXTENDED WARRANTY. I WAS GIVEN THE RUN AROUND FOR WEEKS BY THE CUSTOMER SERVICE DEPARTMENT BEFORE FINALLY BEING TOLD THAT THEY WOULD NOT COVER THE REPAIRS. *JB

NHTSA ID

10151758

Incident

Mar 15, 2005

Mileage

46,000 mi

DT*: THE CONTACT STATED THE VEHICLE LOST POWER MULTIPLE TIMES. THE FIRST TIME THE ENGINE COIL BURNED OUT AND WAS REPLACED BY THE DEALERSHIP. THE SECOND TIME THE CATALYTIC CONVERTER WAS PLUGGED AND ENGINE BOLTS HAD BROKEN. THE DEALERSHIP REPLACED THE CATALYTIC CONVERTER AND THE BOLTS. DURING THE THIRD OCCURRENCE THE FOOT THROTTLE BODY SENSOR FAILED AND THE DASH LIGHTS INTERMITTENTLY ILLUMINATED. THE THROTTLE BODY SENSOR WAS REPLACED BY THE DEALERSHIP. DURING ALL THE OCCURRENCES THE VEHICLE LOST POWER WITHOUT WARNING.

NHTSA ID

10150955

Incident

Jan 30, 2006

Mileage

15,000 mi

DT*: THE CONTACT STATED WHILE DRIVING AT 30MPH, THE VEHICLE STALLED. THE VEHICLE DID NOT RESTART AND WAS TOWED TO THE DEALERSHIP FOR INSPECTION AND REPAIRS. THE DEALER DISCOVERED THE FUEL LINE HAD FRACTURED AND BROKE. THE DEALER REPAIRED THE FUEL PUMP AND THE VEHICLE OPERATES NORMALLY.

NHTSA ID

10150502

Incident

Feb 10, 2006

Mileage

40,000 mi

IN AUGUST 2002, I PRODUCED BRAKES IN 542 DEPT. AT DELPHI CHASSIS SYSTEMS, DAYTON, OHIO. THE DEPARTMENT WAS SCHEDULED TO CEASE WORK 2 MONTHS AFTER THE END OF GM F-CAR PRODUCTION I WAS PLACED IN INSPECTION BEHIND BRAKE ASSEMBLY. I INSPECTED ALL BRAKES PRODUCED AS SERVICE PARTS. BEFORE I ARRIVED, THERE WERE PROBLEMS WITH POROSITY IN THE BRAKE CASTINGS. INSTEAD OF REQUIRING THE CASTINGS PRODUCER TO BRING IN AN X-RAY MACHINE, GENERAL FOREMAN SAM HANAKERI, ON ORDERS FROM VP GUY HACHEY, INSTALLED AN AIR GUN DRIVER AND WATER TANK TO CHECK PARTS AS THEY RAN. THE AIR GUN WOULD SHOOT A SPECIAL SCREW CONNECTED TO A COMPRESSED AIR CONNECTION, AND THE PART WAS DUNKED WHILE THE COMPRESSED AIR WAS ATTACHED TO THE BRAKE CASTING. THE PROBLEM: THE COMPRESSED AIR ATTACHMENT CROSS THREADED ABOUT 5% OF THE CONNECTION HOLES IN THE CASTING. SINCE THESE CONNECTIONS HAVE TO WITHSTAND HYDRAULIC PRESSURE WHEN THE BRAKES ARE IN USE, CROSS THREADING CAUSES LEAKS AND POTENTIAL BRAKE FAILURE. A GM ASSEMBLY PLANT HAD ISSUED A PRR FOR THE CROSS THREADING, BUT ONLY FOR ONE SIDE OF THE BRAKES DELPHI MANAGEMENT ONLY WANTED TO INSPECT THE THREADS ON THE BRAKES MENTIONED IN THE GM PRR, NOT MIRROR IMAGES. THEY KNEW THAT THE INSPECTION PROCESS DAMAGED BOTH SIDES, BUT WANTED TO IGNORE THE PROBLEMS ON THE NON PRR SIDE. SAM HANAKERI, GF, ORDERED ME TO INSPECT ONLY THE PRR SIDES. HE STATED THAT THE INSPECTION PROCESS CAME FROM GUY HACHEY, AND COULD NOT BE CHANGED OR IMPROVED. I INSPECTED THESE PARTS 60 DAYS. SAM HANAKERI OBJECTED TO THE SCRAP RESULTING FROM MY FINDING BAD THREADS, STATING THAT PREVIOUS INSPECTORS HAD FOUND LESS. I TOLD HIM THAT I SIGNED THE FORMS, AND AS LONG AS MY NAME WAS ON THE FORMS, THEY WOULD REFLECT WHAT I SAW. THESE SERVICE PARTS ARE STILL ON SHELVES. THE ASSEMBLY PARTS HAVE BEEN IN USE SINCE 2002. THE INSPECTION FORMS ARE STILL IN EXISTENCE, MAINTAINED BY BILL ENGLUND AT DELPHI NEED MORE BRAKE PLANT.*JB

NHTSA ID

10150496

Incident

Aug 31, 2002

DT*: THE CONTACT STATED UPON TURNING ON THE VEHICLE, THE DOOR PANEL BEGAN TO SMOKE, AND THEN THE FLAMES WERE COMING FROM THE WINDOW SWITCH. THE DEALERSHIP DETERMINED IT WAS A FIRE OF AN UNKNOWN IGNITION SOURCE. THE WINDOW SWITCH AND DOOR PANEL NEED TO BE REPLACED.

NHTSA ID

10149210

Incident

Jan 24, 2006

Mileage

95,000 mi

FUEL PUMP FAILED ON HIGHWAY TRIP. VEHICLE HAS ONLY 40000 MILES. SAFETY HAZARD IN THAT I HAD A HARD TIME GETTING THE VEHICLE SAFELY TO THE SHOULDER. *AK CAR ALSO HAS A BRAKE VIBRATION AND HAS HAD IT A WHILE. HAVE NEVER TAKEN TO DEALER AS BRAKING DISTANCE HAS NOT BEEN COMPROMISED YET.

NHTSA ID

10148418

Incident

Jan 19, 2006

Mileage

40,120 mi