2004 Chevrolet Corvette

In its June 30, 2010 response to ODI's Information Request letter, General Motors (GM) identified the leak source as cracks in either the fuel tank cross-over tube quick connector (connector) and/or the hot-plate weld joint of the connector to the tank.The root causes are attributed to errors in connector material processing, variations in the welding process, and high stresses placed on the driver's side connector during vehicle use.GM also identified the scope of the subject vehicles involved to be those produced from approximately October 22, 2003 through March 19, 2004.GM does not believe the cracks represent an unreasonable risk to motor vehicle safety based on factors that include; low rate of fuel leaking to the ground, detectable fuel odor, the cracks are at the top of the tank, leaks are detectable during refueling, small quantities of fuel that leaks out, and no associated property damage or personal injury claims.On August 13, 2010, GM issued a Special Coverage Adjustment to remedy fuel tank quick connector leaks and extend the warranty for this issue to 10 years or 100,000 miles in certain 2004 Chevrolet Corvette and Cadillac XLR vehicles.Vehicle owners will be notified by mail of the adjustment and will also be entitled to reimbursement for previously paid repairs covered under the adjustment.(See file for, SERVICE BULLETIN 10150: SPECIAL COVERAGE ADJUSTMENT-FUEL TANK QUICK CONNECTOR LEAK).The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency reserves the right to take further action if warranted by the circumstances.

IN 2001, GENERAL MOTORS (GM) ISSUED CUSTOMER SERVICE CAMPAIGNS 1044 AND 1044A TO ADDRESS A CONDITION WHERE THE STEERING COLUMN WOULD FAIL TO UNLOCK DURING THE INITIAL KEY-IN AND START-UP IN CERTAIN MY 1998-2000 CORVETTE VEHICLES.HOWEVER, ODI CONTINUED TO RECEIVE COMPLAINTS CONCERNING STEERING COLUMN LOCKUP ON CORVETTE VEHICLES.AS A RESULT, PE02-054 WAS OPENED AND LATER UPGRADED TO EA02-031 FOR MY 1997-2001 SUBJECT VEHICLES.ODI'S ANALYSIS IDENTIFIED CONCERNS WITH POST-REPAIR FAILURES IN VEHICLES SERVICED THROUGH THE CAMPAIGNS, AS WELL AS, FAILURES IN MY 1997-2003 SUBJECT VEHICLES NOT INCLUDED IN THE CAMPAIGNS.(NOTE: THE MANUFACTURER FAILURE DATA ABOVE IS LIMITED TO MY 1997-2003 VEHICLES THROUGH 10/17/2003.)ON FEBRUARY 6, 2004, GM NOTIFIED NHTSA OF A SAFETY DEFECT IN MY 1997-2004 CORVETTE VEHCLES EQUIPPED WITH MANUAL TRANSMISSIONS AND MY 1997-2000 CORVETTE VEHICLES WITH AUTOMATIC TRANSMISSIONS.THE NOTIFICATION STATED THAT IF THE VOLTAGE AT THE POWERTRAIN CONTROL MODULE (PCM), WHICH WAS DESIGNED TO SHUT DOWN THE FUEL SUPPLY WHEN THE STEERING COLUMN FAILED TO UNLOCK AND THE CUSTOMER TRIED TO DRIVE THE VEHICLE, IS LOW OR INTERRUPTED, THE FUEL SHUT OFF MAY NOT OCCUR.AS A RESULT, THE CUSTOMER COULD DRIVE THE VEHICLE WHILE THE STEERING COLUMN WAS LOCKED CAUSING THE DRIVER TO LOSE STEERING CONTROL AND POSSIBLY CRASH WITHOUT WARNING.GM WILL INSTRUCT OWNERS TO BRING THEIR VEHICLES TO A DEALER TO HAVE THE PCM REPROGRAMMED FOR MANUAL TRANSMISSION VEHICLES AND THE ELECTRIC COLUMN LOCK DISABLED FOR AUTOMATIC TRANSMISSION VEHICLES.ODI WILL MONITOR THE EFFECTIVENESS OF THE REMEDY IN THE MANUAL TRANSMISSION VEHICLES AND TAKE FURTHER ACTION IF WARRANTED.

- Fuel tank leaks - gasoline puddles under car, heavy fumes - Fire / explosion hazard - Confirmed by local mechanic as existing problem in that year - Inspected and confirmed by selling dealer - trying to repair - No auto warning, smell of fumes and gas on garage floor day after delivery of car

NHTSA ID

11605841

Incident

Apr 12, 2024

When I start my vehicle, the steering wheel locking system does not disengage and the steering wheel stays locked.

NHTSA ID

11583610

Incident

Apr 17, 2024

The contact owns a 2004 Chevrolet Corvette. The contact stated while driving, the vehicle failed to move farther than five feet before the vehicle stalled and lost motive power. The pull-out key and wait-ten-seconds message were displayed. The contact had to release the key from the ignition and restart the vehicle. The contact called an independent mechanic and was unable to determine the cause of the failure. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not notified about the failure. The failure mileage was approximately 30,000.

NHTSA ID

11560269

Incident

Jan 1, 2013

Mileage

30,000 mi

A month after I purchased the car with approximately 40k miles, I took the car in for an oil change at the dealership and was told there was a major leak in the left fuel tank and at the crossover tube. This leaking fuel is leaking onto the exhaust. It would cost at least $4,000 to repair. I can not afford this. It is too dangerous to drive. I have no other car. Supposedly, my vin number is 200 numbers away from being included in the recall for the same issue and that you have 43 pages of complaints about. Did I mention that the crossover tube is a backordered part because so many are needed because when you pull the current one out, it breaks and a new one is needed?

NHTSA ID

11556634

Incident

May 1, 2022

Strong Fuel smell near the fuel filler when car is parked in the garage.

NHTSA ID

11553638

Incident

Nov 5, 2023

Fuel tank leaking/fumes. Appeara to be crossover tube connection connecting the 2 tanks.

NHTSA ID

11542550

Incident

Sep 1, 2023

The contact owns a 2004 Chevrolet Corvette. The contact stated while driving approximately 35 MPH, the odor of gasoline was detected by the contact and his wife. The contact stated no warning light was illuminated. The contact stated that the odor of gasoline was strongest in the cabin after refueling the vehicle to a full tank. The contact had taken the vehicle to a local dealer, where it was diagnosed and determined that a cross fill tube needed to be installed. The vehicle had been repaired. The contact stated that the gasoline odor was again detected while driving at various speeds. The contact researched online and related the failure to NHTSA Action Number: PE10015 (Fuel System, Gasoline). The manufacturer had not been informed of the failure. The failure mileage was approximately 44,000.

NHTSA ID

11536947

Incident

Jun 17, 2023

Mileage

44,000 mi

In 2011 Chevrolet acknowledged an issue with the fuel system as the the attached letter states. I was not the owner of the vehicle in 2011 and since the issue was not elevated to an official recall it did not show up on the car fax report and I thus was unaware of this potential safety hazard. My car has now developed all the symptoms of the fuel tank leak with fumes in the car and gas dripping on the garage floor when parked. Although my car only has 30,000 miles the end date for GM to provide repair was August 11, 2011. The significant risk to passengers, the car, and my home when the car is parked in the attached garage is unacceptable as caused by a faulty engineered fuel modification in this model year. The fuel leak is both a safety and environmental risk and should warrant a recall and GM to mitigate the costs. Their liability for a faulty engineered system should not have a time limit.

NHTSA ID

11515690

Incident

Apr 2, 2023

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

This Preliminary Information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get record a sound clip or take a video of the noise for assessment by engineering. Technician will need to call General Motors Technical Assistance Center for further assistance.

This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester  and Vehicle Data Recorder tools, giving website address and step by step instructions to complete the update.

This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature.

This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature.

This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed for the vehicle in question and its applications. Technician should not use the information that is provided by the antilock braking system tire size selection.