2004 CHEVROLET CORVETTE Complaints

LEFT SIDE GAS TANK CROSSOVER TUBE LEAKING, 2004 CORVETTE Z06. CONFIRMED WITH A REPAIR BY AN AUTHORIZED GM REPAIR FACILITY. PAID OUT OF POCKET. FUEL TANK COULD ONLY BE FILLED UP 1/2 FULL OR A HEAVY FUEL SMELL AND/OR LEAKING WOULD OCCUR. *TR

MY 2004 CORVETTE HAS A PROBLEM WITH FUEL LEAKAGE WHEN I FILL IT I GET A HEAVY ODOR OF GASOLINE IM AFRAID IT MAY BURN MY HOUSE DOWN IF I LEAVE IT IN THE GARAGE NOW. *TR

1. TRAVELING IN HIGH SPEED LANE OF FREEWAY VEHICLE SUDDENLY STOPPED RUNNING WITHOUT ANY FOREWARNING. 2. FIRST AND ONLY TIME THIS OCCURRED 3. DEALER REPLACED THE IN TANK FUEL PUMP. *TR

CONSTANT FUEL SMELL AND FUEL LEAKING DRASTICALLY FROM REAR OF CAR IN TWO PUDDLES WHEN TANK IS FULL, OR AFTER SOMEWHAT SHARP TURNS ARE MADE. UPDATED 09/16-10 *BF PICTURES RECEIVED. UPDATED 09/20/10 *TR

TL* THE CONTACT OWNS A 2004 CHEVROLET CORVETTE. THE CONTACT STATED WHEN REFUELING THE VEHICLE, THERE WAS AN ABNORMALLY OVERPOWERING GASOLINE ODOR. THE CONTACT STATED THE ODOR WAS MOST PROMINENT WHEN THE FUEL TANK WAS LESS THAN ONE HALF FULL. IN ADDITION, THE CONTACT STATED FUEL WAS LEAKING FROM THE VEHICLE AND CAUSING DISCOLORATION. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE CONTACT WAS AWAITING REPAIRS. THERE WAS A PREVIOUS DEFECT INVESTIGATION OF THE FAILURE (NHTSA ACTION NUMBER: PE10015- FUEL SYSTEM STORAGE TANKS) BUT DID NOT RESULT IN A RECALL. THE CURRENT AND FAILURE MILEAGES WERE APPROXIMATELY 12,900.

OWN A 2004 CORVETTE Z06 WITH 66,000 MILES. AT ABOUT 63,000 STARTED TO SMELL GAS FUMES. BOUGHT A NEW GAS CAP BUT STILL SMELLED FUMES. TOOK IT TO A CERTIFIED CORVETTE MECHANIC AND FOUND THE LEAK TO BE THE LEFT FUEL TANK AT THE CROSSOVER PIPE. HE REPLACED BOTH FUEL TANKS AND CROSS OVER FOR AROUND $1900. MY BROTHER ALSO OWNED A 2004 CORVETTE WITH ABOUT THE SAME MILEAGE AND HAD THE SAME PROBLEM. HE TOOK HIS TO A DEALER AND THEY REPLACED BOTH FUEL TANKS AND CROSSOVER FOR AROUND $2700. *TR

ON THURSDAY, AUG. 12, 2010, I STOPPED BY AT A GAS STATION TO FILL UP MY GAS TANK ON MY 2004 CHEVROLET CORVETTE COUPE. AFTER TRAVELING APPROXIMATELY 4 MILES FROM THE GAS STATION, I NOTICED A GAS LEAK UNDERNEATH COMING FROM THE LEFT DRIVER'S SIDE NEAR THE GAS TANK AREA. AFTER DISCOVERING THE PROBLEM, I IMMEDIATELY DROVE THE CAR TO A CHEVROLET SERVICE DEALERSHIP. AFTER HAVING A CERTIFIED GM MECHANIC LOOKING AT THE PROBLEM, THEY DISCOVERED IS WAS A DEFECTIVE TANK CONNECTOR (CROSSOVER PIPE) THAT CRACKS UNDER STRESS. WHAT NEEDED TO BE REPLACED WAS THE O-RING SEALS AND CONNECTOR PIPE ($250). THE LABOR CHARGE FOR REPLACING THESE PARTS ON A 2004 CORVETTE WAS $845. IT IS ALSO MY UNDERSTANDING THAT IN 2003 TO 2004, GM HAD THESE CROSSOVER PIPES CHANGED FROM A RUBBER TO A STEEL MATERIAL BECAUSE OF GAS AND HIGHWAY EMISSIONS. I WOULD LIKE TO MAKE STATEMENT TO EVERY OWNER OF 2004 CORVETTE, THAT THERE IS IN FACT A DEFECTIVE CROSSOVER PIPE THAT WILL LEAK GASOLINE AND WILL EVENTUALLY CAUSE A FIRE HAZARD IF IT IS NOT REPLACED. *TR

I OWN A 2004 CORVETTE AND AM VERY CONCERNED ABOUT THE MANY REPORTS OF A MFG. DEFECT IN THE FUEL TANK CROSSOVER QUICK CONNECT, CAUSING A FUEL LEAK AND POTENTIAL FIRE, LOSS OF LIFE. "THE CROSSOVER QUICK CONNECT IS AN INJECTION MOLDED COMPONENT MOLDED AT VIKING PLASTICS USING A MATERIAL PROVIDED BY POLYONE CORP. DURING THE COMPOUNDING PROCESS AT POLYONE CORP. ON SEPTEMBER 30, 2003, POLYONE CORP. MIS-PROCESSED A 3,000 POUND BATCH OF THE CROSSOVER QUICK CONNECT MATERIAL WHICH SIGNIFICANTLY DEGRADED THE MOLECULAR WEIGHT OF THE GLASS FILLED OLEFIN MATERIAL AND ULTIMATELY THE FRACTURE TOUGHNESS OF THE QUICK CONNECT." "POLYONE ALSO KNOWINGLY REPORTED INCORRECT PELLET SIZE ON THE MATERIAL CERTS." SUSPECT THAT COMPONENTS THAT SHOULD HAVE BEEN SCRAPPED, WERE RE-INTRODUCED INTO PRODUCTION ON AT LEAST TWO OTHER OCCASIONS." THIS IS FROM A GM LETTER FROM TERRY M. STONE TO DAVE REEK ON 10/08//2004 SUBJECT: FUEL LEAKS-ROOT CAUSE. ALSO IN ANOTHER LETTER PE 10-015 N100150 RESPONSE DATED JUNE 30, 2010 ON PAGE 13: "FUEL TANKS WITH SUSPECT QUICK CONNECTORS USING MATERIAL COMPOUNDED ON SEPTEMBER 30, 2003 AND JANUARY 7, 2004 WERE INSTALLED IN VEHICLES PRODUCED FROM APPROXIMATELY OCTOBER 22, 2003 THROUGH MARCH 19, 2004." "GM DOES NOT BELIEVE THAT THE ALLEGED DEFECT REPRESENTS AN UNREASONABLE RISK TO VEHICLE SAFETY." I STRONGLY DISAGREE WITH GM'S STATEMENT. ANY FUEL LEAK CAUSED BY A MFG. DEFECT POSES A MAJOR RISK TO VEHICLE SAFETY DUE TO THE POTENTIAL OF FIRE FROM LEAKING GAS. ONCE AGAIN, THERE HAVE BEEN MANY REPORTS OF THIS DEFECT AND I AM VERY CONCERNED THAT MY CAR COULD HAVE A DEFECTIVE GAS TANK WHICH SHOULD BE REPLACED BY GM IF A LEAK OCCURS. I ENCOURAGE THE NHTSA TO ISSUE AN IMMEDIATE RECALL OF THESE DEFECTIVE TANKS ON 2003/2004 CORVETTES/CADILLAC XLR VEHICLES BEFORE THERE IS A FIRE OR LOSS OF LIFE. UPDATED IVOQ 11/02/10 *TR

I BOUGHT THE 2004 VETTE COUPE ON 5-29-10 FROM A LOCAL DEALER. THE CAR SEEMED CLEAN. I HAVE PUT A LITTLE OVER 1,000 EASY MILES ON THE CAR IN 9 WEEKS. I STARTED TO NOTICE A SMELL COMING FROM THE CAR WHEN I WOULD GET HOME AND BEGAN TO RUN FANS TO GET IT OUT OF THE GARAGE. I FINALLY TOOK IT TO A LOCAL CADILLAC DEALER SINCE I WAS NOT SURE I COULD TRUST THE DEALER THAT SOLD ME THIS CAR WITH A PROBLEM AND THEY FOUND A GAS LEAK AT THE JOINT WHERE THE TUBE THAT CONNECTS THE TWO TANKS COMES OUT OF THE RIGHT TANK. IT ONLY DRIPS WHEN IT HAS BEEN DRIVEN BUT IS NOW QUITE BAD. I HAVE NOT DARED DRIVE IT FOR THE LAST WEEK. IT HAS NOT BEEN WORKED ON BECAUSE I WAS ADVISED TO CALL GM TO SEE IF THEY COULD HELP OUT ON THIS COSTLY REPAIR. I HAVE NOT HEARD BACK FROM THEM AS YET. THE GM REP DID ASK ME TO TAKE IT BACK TO THE ORIGINAL SELLER FOR ANOTHER INSPECTION EVEN THOUGH ANOTHER DIVISION OF THEIR COMPANY HAS ALREADY IDENTIFIED THE PROBLEM AND EVEN SHOWED ME THE LEAKING LOCATION. THIS IS A VERY DANGEROUS SITUATION AS GAS NOW DRIPS ON THE GROUND IN FRONT OF THE RIGHT REAR TIRE. ANY THING YOU CAN DO TO SEE TO IT THAT THIS SITUATION IS CORRECTED QUICKLY MAY SAVE SOMEONE'S LIFE. I CONSIDER MYSELF FORTUNATE TO HAVE FOUND OUT WHAT WAS WRONG WITHOUT BEING HURT OR KILLED. *TR

CHEVROLET CORVETTE 2004 START NOTICING A FUEL ODOR IN THE GARAGE BROUGHT TO THE SHOP THEY REMOVE THE DRIVER SIDE FUEL AND DISCOVER THAT IT WAS CRACK AROUND THE CROSSOVER PIPE. *TR