2004 CHEVROLET CORVETTE Fuel/propulsion System Problems

- 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

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?

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

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.

Purchased the vehicle in 2015. That same purchased date I filled the vehicle with fuel. The following day my garage was totally covered with gas fumes. No tech could find the problem. On Feb 22 2023 while filling up, gas was pouring out the bottom left side . This is very dangerous. Come to find out that many others have had the same problem. There is a manufacturer defect of the gas tank housing tube . I cannot drive the vehicle because it’s to dangerous and to costly to repair.

Drivers side fuel tank/system leak Leaking fuel in this area can/will result in a catastrophic fire which could lead to injury or death The problem just occurred but is a common problem for this generation Z06 Corvette The odd thing is no warning light, check engine light or messages displayed, just the smell of fuel and 18 inch puddle on the floor beneath the drivers side fuel tank. The fuel level according to the gauge is 1/2 tank.

I have owned this vehicle the last 6 years. When the amount of fuel is over one-half tank, there is an abnormal odor of fuel. When pulling into the garage, there's fuel leaking if over one-half tank. Once the engine is cut off the fuel leak ceases. To control the issue, I keep the fuel level at less than one-half tank. A certified local mechanic determined the fuel tank and crossover tube cross connector needed to be replaced. The vehicle has not been repaired. The mechanic stated the failure was related to NHTSA Action Number: PE10015 (Fuel System, Gasoline). The approximate failure mileage was 26,500, when i bought the car. The mechanic stated that GM did issue a service bulletin around 2010 stating that GM would make repairs if the failure occurred within 10 years/100,000 miles. The local GM dealer will not repair my vehicle since it is out of time frame window. It's not fair to those who bought the car after the 10-year cutoff point. or do not drive these vehicles very much.

Left side fuel tank developed a leak- this is a problem known to GM- they offered warranty repairs for ten years-I purchased the vehicle after this additional warranty had expired- my complaint is this is a known defective part which I would replace at my expense however GM has discontinued this part- I feel that while GM will no longer cover the cost of parts and labor the replacement parts should be available

The vehicle has a fuel leak. I just purchased this vehicle a few weeks ago, it's 16 years old and has only 36,000 miles on it. It smelled terribly of fuel when I purchased it. I had the vehicle looked at and it has a fuel leak where the quick connectors connect to the fuel tanks. Anyhow, there's a special coverage adjustment which extended the warranty to 10 yrs/100,000 miles. I'm obviously outside of those parameters, but I feel that since the manufacturer admitted fault and stated that my particular VIN is affected, they should be held accountable for fixing a safety issue with my vehicle. How they got away with issuing a special coverage adjustment for such an issue rather than a simple recall is beyond me.

leaking left fuel tank

Have been in contact with 2 employees from GM, called and left voicemails and sent emails. No reply after it was requested that I take the Corvette to my local dealership for diagnosis. The ECL motor is not working property, causing the steering wheel to lock up and fuel supply to shut off. Sent attachment with diagnosis; however, no reply. GM indicated that this was previously fixed, but it obviously was not. My assertion is that there should not be a expiration date on safety recalls, and the ECL motor is not working properly creating a very dangerous situation. This happens every time that I drive the car. There have been several instances of me starting the car, pulling into traffic, and then the car shuts down. It has been very scary as I pull the key and wait 10 seconds to restart the car. Sometimes I have to do it twice. It is my contention that GM should be responsible for fixing this problem that was previously identified by GM as an issue/concern.

GAS SMELL COMING FROM REAR OF CAR AFTER DRIVING. NO VISIBLE LEAKS, BUT LEAKING FUEL VAPOR.

Mileage: 22,000

GASOLINE LEAK FROM A CROSSOVER PIPE CONNECTION CONNECTING THE TWO GAS TANKS. DRIPPIG RAW FWEL ONTO A HOT EXHAUST SYSTEM AND TRANSMISSION. COMMOM PROBLEM ON TNIS YEAR AND MODEL. REPAIR WAS COVERED FOR FIRST 10 YEARS AND 100,000 MILES BY MANUFACTURER. STILL AND ISSUE WITH CARS NOT REPAIRED.

Mileage: 98,000

THE FUEL TANK LEAKS WHEN THE ENGINE IS RUNNING. IN 2010, THIS CONDITION RESULTED IN AN ADDITIONAL WARRANTY FOR THE ISSUE THAT EXPIRED IN 2014, BUT I HAVE A LOWER MILEAGE CAR (LESS THAN 18,000 MILES) SO THE ISSUE DID NOT OCCUR UNTIL NOW. THE PROBLEM EMERGED SUDDENLY AFTER FULLY REFILLING THE FUEL TANK RECENTLY.

Mileage: 17,550

TL* THE CONTACT CALLED ON BEHALF OF AN OWNER OF A 2004 CHEVROLET CORVETTE. THE CONTACT STATED THAT THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC DUE TO A FUEL LEAK. THE MECHANIC DETERMINED THAT THE PLASTIC OPENING OF THE FUEL TANK, WHICH CONNECTED A PRIMARY TANK TO THE SECONDARY TANK HOSE, WAS FRACTURED AND FUEL WAS LEAKING. THE VEHICLE NEEDED A NEW FUEL TANK AND CROSSOVER COMPONENTS. THE VEHICLE WAS NOT REPAIRED. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 39,000.

Mileage: 39,000

I BOUGHT A 2004 CORVETTE USED WITH 67K MILES ON IT. THE DEALERSHIP HAD ONLY FILLED THE TANK TO LESS THAN HALF FULL.,AFTER MY FIRST FILL UP GAS POURED OUT FROM UNDERNEATH, BEHIND DRIVERS SIDE TIRE. I PAID $ 16,500 FOR THE CAR , SO I TOOK IT BACK TO DEALER AND THEY SAID THEY WOULD REPAIR. AFTER ABOUT 10 DAYS I WENT TO DEALER AND NOTICED THE CAR HAD NOT EVEN MOVED. HE SAID THEY DID NOT KNOW HOW TO FIX IT AND THEY HAD ANOTHER DEALERSHIP IN ANOTHER STATE THAT THEY WOULD NEED TO TAKE IT TO. I LEFT WITH THE CAR UNREPAIRED.IS THERE ANYTHING I CAN DO ? I BELIEVE IT IS A RECALL ON THE CROSSOVER TUBE AND THE RECALL HAS EXPIRED. CLOSE TO A $1500 TO $1800 REPAIR

Mileage: 67,400

THERE IS A KNOWN LEAK IN THE LEFT FUEL TANK. MY VEHICLE HAS SYMPTOMS BUT WAS NEVER FIXED. VEHICLE IS 15 YEARS OLD BUT ONLY 76,000 MILES.

Mileage: 76,000

ONE DAY I NOTICED THAT MY GARAGE HAD A STRONG GAS SMELL. OVER TIME, I REALIZED THAT IF MY GAS TANK WAS APPROX. BELOW 1/3 FULL IT DID NOT SMELL. CHEVROLET INFORMED ME IT WAS COVERED FOR 100,000 MILES/10 YEARS WHICHEVER COMES FIRST. HOWEVER, I NEVER KNEW A RECALL COULD HAVE A TIME LIMIT BECAUSE OBVIOUSLY THIS IS A SAFETY ISSUE. I WROTE CHEVROLET A CERTIFIED LETTER DESCRIBING MY PROBLEM WITH NO RESPONSE. THIS IS A COMMON PROBLEM WHICH IS CONFIRMED BY LOOKING AT YOUR SITE.

Mileage: 42,000

GASOLINE VAPORS ARE LEAKING FROM FUEL VENT AND TRANSFER LINES, CREATING AN EXPLOSION HAZARD. THE PROBLEM IS MORE OF AN ISSUE WHEN PARKED ALLOWING A SPARK TO IGNITE THE FUEL VAPORS.

STRONG FUEL SMELL AFTER FILLING THE GAS TANK. GOES AWAY ONCE TANK IS LESS THAN 1/2 FULL AS READ BY THE GAUGE.

Mileage: 25,000

AFTER FILLING THE GAS TANK STRONG GAS SMELL COMING FROM FILL AREA BUT NO VISIBLE FUEL LEAK THE GAS SMELL DOES NOT GO AWAY AFTER DAYS AND MANY MILES DRIVEN.

Mileage: 11,400

TAKATA RECALL VISIBLE GASOLINE LEAKAGE AFTER VEHICLE HASN'T BEEN PARKED OVER A PERIOD OF MONTHS. THEN I BEGAN TO TAKE NOTES OF WHAT , WHEN , WHERE THIS LEAK WAS OCCURRING, I WOULD FILL THE TANK, PARK THE AUTO IN THE GARAGE . THE NEXT TIME I USED THE VEHICLE, A NOTICEABLE GAS ODOR, SPOT ON THE GARAGE FLOOR WAS NOTED. I STARTED TO PLACE A CARDBOARD UNDER THE FRONT END TO MORE READILY BE ABLE TO OBSERVE THE SUBSTANCE LEAKING. THE ODOR WAS UNMISTAKABLE. SEVERAL OCCURRENCES N SPOTTING IS EVIDENT AFTER HAVING PARKED IN MY GARAGE . THE AUTO WAS PARKED OVERNIGHT IN MY GARAGE. I AM LISTING THE LATEST CALENDAR DATE AND PHOTO. I HAVE OTHER DATES IN MY NOTEPAD. 2) MY SEATBELT OCCASIONALLY WILL NOT LOCK. I HEAR THE CLICK OF A SEATBELT LOCK THEN UPON DRIVING AWAY FROM MY HOME ~ ,25 MILES ~ MY SEATBELT UNLOCKED THROUGH NO FAULT OF MY OWN. 3) AIRBAG CANNOT BE CHECKED FOR EFFECTIVENESS .

Mileage: 88,010

AFTER FILLING UP MY VEHICLE, DROVE HOME SAT IN DRIVEWAY FOR A FEW MINUTES, ADJUSTED RADIO STATIONS, I SMELLED A STRONG ODOR OF GAS, TURN VEHICLE OFF STILL SMELLING GAS, LOOKED UNDER DRIVER'S SIDE OF VEHICLE AND SEEN A PUDDLE OF FLUID, PUT MY FINGER IN IT AND IT WAS GAS!, I'M THINKING NOW THAT'S WHY THE USED CAR DEALERSHIP ONLY PUT A HALF A TANK OF GAS IN IT! PURCHASED THIS 2004 CORVETTE BACK IN MARCH 2018 HAVE ONLY PUT 60 MILES ON IT, IT NOW ONLY HAS 14,936 MILES ON IT! WHAT COULD HAVE HAPPENED IF I PARKED THE CAR IN SHOPPING CENTER PARKING LOT, WITH A CIGARETTE THAT JUST BEEN THROWN DOWN?

Mileage: 14,936

PUT 15 GALLONS OF GAS INTO TANK, IMMEDIATELY NOTICED GAS SMELL INSIDE CAR AND OUTSIDE, DROVE APPROXIMATELY 10 MILES AND SMELL INCREASED. STOPPED CAR AND IMMEDIATELY SAW GAS DRIPPING IN FRONT OF LEFT REAR TIRE AND FORMING A PUDDLE, STOPPED DRIPPING AFTER 5 MINUTES OR SO. DROVE TO HOME AND LET SIT UNTIL MORNING, HAD CAR TOWED TO CHEVROLET DEALER THAT MORNING. TOLD BY DEALER THAT GAS TANK IS CRACKED AND CROSSOVER PIPE IS DEFECTIVE. REPAIRS TO BE NEAR $3000.

Mileage: 74,100

FUEL LEAKING FROM FUEL TANK WHEN I FUEL

FUEL TANK CROSSOVER TUBE HAS A CRACK. I FOUND A SPECIAL COVERAGE #10150 THE NHTSA ISSUE IN AUGUST 2010, BUT HAS EXPIRED. I CONTACTED GM AND ASKED FOR ASSISTANCE, TO WHICH THEY REFUSED. MY CAR HAS 20K MILES ON IT. I HAVE PERFORMED ALL MAINTENANCE, KEEP IT METICULOUSLY CLEAN AND NOT DRIVE IT RECKLESSLY. IF I FILL UP THE CAR THERE IS A NOTICEABLE FUEL LEAK TO THE POINT THERE IS A PUDDLE UNDER THE CAR. AT THIS POINT I CANNOT DRIVE THE CAR FOR FEAR OF FIRE AND THE CAR WILL NOT PASS AN EMISSION TEST. I PURCHASED THE CAR IN ALASKA IN 2009 WITH 9K MILES ON IT. I NEVER RECEIVED ANY INFO REGARDING THE NHTSA #10150 SPECIAL COVERAGE. THE ESTIMATED COSTS OF REPAIR IS BETWEEN $3000 TO $4500. IS THERE ANY ASSISTANCE THE NHTSA CAN PROVIDE?

Mileage: 20,000

GASOLINE SMELL

Mileage: 21,000

DRIVER SIDE GAS TANK HAS BEEN LEAKING FOR ABOUT A MONTH AM HAVING HEAVY FUEL SMELL WHEN CAR IS PARKED AND AFTER FUELING UP

Mileage: 43,400

CAR BEGAN GUSHING FUEL OUT OF TOP OF TANK ONCE FUEL SYSTEM PRESSURIZED. HIRED ROLLBACK TO TAKE TO MECHANIC WHO INFORMED THAT CROSSOVER LINE WAS BAD. MECHANIC ALSO STATED THAT THERE WAS A RECALL FOR THIS ISSUE. I AM SECOND OWNER OF CAR, WHICH ONLY HAS 2150 MILES ON IT, SO KNEW NOTHING ABOUT IT. I WOULD LIKE TO BE REIMBURSED FOR THIS EXPENSE!

Mileage: 2,150

STRONG SMELL OF GAS WHEN PARKED IN GARAGE,ALWAYS USED CARPORT UNTIL NOW SO I NEVER NOTICED. BUT NOW HAVE A GARAGE, BUT I AM AFRAID OF STRONG FUEL SMELL MAY BE DANGEROUS. HAS NEW GAS CAP AND NO GAS LEAK.

I HAD A STRONG FUEL SMELL IN MY GARAGE AND A SMALL PUDDLE OF FUEL ON MY GARAGE FLOOR. I HAD GOTTEN A RECALL NOTICE FROM GM SOME TIME AGO, TOOK MY CAR TO THE DEALER AT THE TIME AND THEY SAID THEY COULD DO NOTHING UNLESS THERE WAS A LEAK. NOW, I HAVE THE LEAK, BUT GM REFUSES TO FIX THE PROBLEM BECAUSE SOME TIME PERIOD HAS EXPIRED. THIS LEAK HAS BEEN REPAIRED BY ANOTHER SHOP, BUT I AM OUT OVER $2,000 FOR A PROBLEM GM KNEW COULD CAUSE THE CAR TO BURN UP. I SEEK FOR GM TO REIMBURSE ME FOR THIS REPAIR OF A CRITICAL SAFETY ISSUE.

Mileage: 37,954

LEAVING SERVICE STATION AFTER FILLING CAR WITH FUEL GAS FUMES WERE FILLING THE CAR. PARKED IT IN GARAGE AND NEXT MORNING GARAGE STUNK OF GAS FUMES. BACKED CAR OUT OF GARAGE AND SAW NO FUEL LEAKING BUT FUMES STILL VERY BAD IN CAR. CALLED LOCAL CHEVROLET DEALER AND THEY SAID THERE WAS NOT A RECALL FOR THIS. HUSBAND TOOK CAR TO AUTO SHOP AND PUT ON HOIST, WHERE A WET SPOT WAS FOUND. MECHANIC SAID THE CONNECTOR TUBE BETWEEN THE TWO GAS TANKS WAS WET FROM THE GASOLINE. NO WAY TO TAKE A PHOTO BECAUSE THE AREA TO LOOK UP AND SEE THE CONNECTOR IS SO SMALL.

Mileage: 52,523

FUEL TANK LEAK AFTER FILLING TANK. SENDS CEL CODE FOR EVAP SYSTEM. FUEL LEAKS FROM TANK ONTO EXHAUST PIPE. DEALER WILL NOT FIX. I NEVER RECEIVED A "RECALL" NOTICE OR BULLETIN.

Mileage: 75,000

FUEL LEAK FROM FUEL LINES OR FUEL TANK. DEALER CHEVROLET WON'T COVER THE CHARGES,THAT IT EXPIRED IN 2014. I JUST BOUGHT THE CAR LAST JULY.PREVIOUS PAST AWAY AND DIDN'T KNOW ANYTHING ABOUT THIS PROBLEM.

Mileage: 56,000

LARGE FUEL LEAK COMING FROM DRIVERS SIDE REAR TIRE AREA. LEAK SEEMS TO COMING FROM THE TOP OF THE FUEL CELL.

Mileage: 50,508

FUEL LEAK FROM PASSENGER SIDE TANK. IF TANKS SHOW ANYMORE THAN 1/2 FULL I GET DRIPPING OF FUEL ON THE PAVEMENT. THIS HAPPENS RIGHT AFTER THE CAR HAS BEEN RUNNING.. STATIONARY OR IN MOTION. THIS IS A SEVERE FIRE HAZARD. THE CHEVROLET DEALER EXPLAINS THAT THIS COMPLAINT HAD AN EXTENDED WARRANTY BUT THAT HAS EXPIRED. GM SHOULD HAVE A SOCIAL OBLIGATION TO FIX A FAULTY DESIGN THAT IS CAUSING A FIRE HAZARD LIKE THIS. *TR

Mileage: 49,225

THIS CAR HAS 23,000 MILES ON IT AND I AM THE ORIGINAL OWNER. IT HAS DEVELOPED SOME SORT OF FUEL LEAK ONE OF THE TWO FUEL TANKS OR THE CONNECTING TUBE WHILE SITTING PARKED THE GARAGE. GM HAS KNOW ABOUT THIS ISSUE FOR YEARS. THEY DID NOT WARN OWNERS OF THESE CARS OF THIS PROBLEM. NOW THAT I HAVE THIS ISSUE I HAVE DISCOVERED THE GM WOULD FIX THIS IF YOU DISCOVERED THIS PROBLEM IN TEN YEARS OR 100,000 MILES. THIS IS A MAJOR SAFETY ISSUE, THE CAR COULD EXPLODE IF A PERSON WALKS BY IT IN A PARKING LOT, IN AN ACCIDENT OR PARKED IN A PARKING STRUCTURE. THIS CAR IS NOW A TICKING BOMB DUE TO THE FAILURE OF GM TO NOTIFY OWNERS OR THIS POTENTIAL PROBLEM. ALL CORVETTES ARE NOT DAILY DRIVERS THAT IS WHY THE MILEAGE IS LOW. THERE ARE MANY CARS OUT THERE WITH THIS PROBLEM. IT IS IMPORTANT THAT GM SHOULD HAVE TO NOTIFY ALL OWNERS OF THIS VINTAGE OF CAR OF THIS ISSUE AND FIX THEM BEFORE PEOPLE GET HURT OR KILLED. NOT ONLY THE OWNERS OF THESE VEHICLES ARE AT RISK, SO IS THE GENERAL PUBLIC.

Mileage: 22,625

I NOTICED A FUEL SMELL IN MY GARAGE FROM MY CAR. I TOOK IT TO A MECHANIC AND HE FOUND THAT THE TANK WAS LEAKING AS DESCRIBED IN GM SERVICE BULLETIN 10150 IN THE CONNECTION OF THE CROSSOVER BETWEEN THE TANKS. THE CAR HAS 56000 MILES ON IT. THIS IS A KNOWN DEFECT CAUSED BY THE USE OF IMPROPERLY MIXED ADHESIVE IN THE CONNECTOR. I CALLED THE NUMBER ON THE SERVICE BULLETIN AND GM SAID THEY WOULD NOT COVER THE FIX ON THIS KNOWN DEFECT BECAUSE THE ARBITRARY TIME THEY CREATED FOR REPAIR ON THIS HAD LAPSED.

Mileage: 56,000

THIS REQUEST INVOLVES A SAFETY BULLETIN [#0400C6], DATED 2/8/2006 RELATING TO THE ELECTRONIC COLUMN LOCK (ECL) FOR APPROXIMATELY 96% OF ALL 220,000+ C-5 GENERATION CORVETTES. 2004 WAS THE LAST YEAR OF PRODUCTION FOR THE C-5 GENERATION. TOTAL PRODUCTION IN 2004 IS ESTIMATED TO HAVE BEEN ABOUT 35,000: OUT OF THIS, 20,861 VEHICLES WERE COVERED BY THE ABOVE SERVICE BULLETIN, BUT AS MINE WAS ASSEMBLED AFTER VIN #45120862 UNTIL ASSEMBLY BEGAN FOR THE 2005 MODEL YEAR (C-6 GENERATION), MY VIN NUMBER WAS NOT INCLUDED ON PAGE 2 OF THE BULLETIN. PRIOR TO THE STEERING COLUMN ON MY CAR LOCKING ON 6/28/2016 I HAD NOT BEEN MADE AWARE THAT THIS PERILOUS CONDITION EXISTED. GM HAS INDICATED THAT IT WILL NOT PROVIDE ANY FUNDS TO OFFSET THE COST OF REPAIRING THIS FAULT BECAUSE IT WAS NOT INCLUDED ON ANY SERVICE BULLETIN. I BELIEVE THAT SERVICE BULLETIN #04006C WAS INTENDED FOR (OR SHOULD APPLY TO) THE ENTIRE C-5 PRODUCTION -- UNLESS THERE IS SOME REASONABLE EXPLANATION AS TO WHY MY VEHICLE HAS BEEN EXCLUDED (SUCH AS A DIFFERENT ECL CONFIGURATION WAS USED, ETC.) IN EITHER EVENT, I FEEL THE COMPANY SHOULD HONOR MY REQUEST FOR A FULL REIMBURSEMENT FOR FUNDS EXPENDED TO REPLACE THE FAULTY ECL. I HAVE WRITTEN A LETTER TO GM EXPLAINING THE FACTS SURROUNDING THIS REQUEST AND HAVE ATTACHED A COPY OF THAT LETTER FOR YOUR REVIEW.

Mileage: 72,504

TL* THE CONTACT OWNS A 2004 CHEVROLET CORVETTE. THE CONTACT STATED WHILE REFUELING THE VEHICLE, FUEL WAS LEAKING FROM UNDER THE VEHICLE. THE CONTACT MENTIONED THAT THERE WAS NO FUEL ODOR OR LEAKAGE WHEN DRIVING THE VEHICLE. THE FAILURE ONLY OCCURRED WHEN THE VEHICLE WAS BEING DRIVEN. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE FILLER NECK NEEDED TO BE REPLACED. NO REPAIRS WAS MADE TO THE VEHICLE. THE FAILURE MILEAGE WAS 19,000.

Mileage: 19,000

THE TOP OF THE LEFT FUEL TANK IS CRACKED AND LEAKING FUEL. THIS IS A KNOWN PROBLEM FOR 2004 MODEL CORVETTE'S AND CADILLAC XLR'S. GM REFUSED TO DO A "RECALL" ON THIS PROBLEM ALTHOUGH IT IS VERY DANGEROUS AND COULD RESULT IN FIRE OR DEATH OF THE OCCUPANTS.

Mileage: 34,700

2004 CORVETTE - FUEL LEAK AT CROSSOVER TUBE. CRACKED FUEL TANK. TANK LEAKS WHEN FUELED. STRONG ODOR OF FUEL IN DRIVER COMPARTMENT. FUEL LEAK ON GROUND AT SERVICE STATION. THIS IS A KNOWN DEFECT AND GM SHOULD BE REQUIRED TO REPAIR THIS DEFECT. HAS NHTSA MADE ANY EFFORT TO REQUIRE GM TO REPAIR OR RECALL THESE CARS? IF NOT, WHY?

SUMMARY: 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. HTTP://WWW-ODI.NHTSA.DOT.GOV/CARS/PROBLEMS/DEFECT/RESULTS.CFM?ACTION_NUMBER=PE10015&SEARCHTYPE=QUICKSEARCH&SUMMARY=TRUE

Mileage: 28,800

SINCE PURCHASING THE VEHICLE USED IN 2005, I ALWAYS SMELLED GASOLINE FUMES AFTER A FILL UP. I ALWAYS ATTRIBUTED IT TO SPILLAGE AND THE FACT THAT THE FILLER TUBE WAS ABOUT A FOOT FROM MY HEAD. THIS YEAR THE FUMES BEGAN TO PERSIST, REGARDLESS OF THE QUANTITY OF GAS IN THE TANK. AFTER RETURNING FROM A 3 WEEK VACATION IN JULY, WE WERE GREETED BY OVERPOWERING GASOLINE FUMES WHEN WE OPENED OUR GARAGE. I AM CERTAIN THAT THE FUMES WERE CONCENTRATED ENOUGH TO START A FIRE, HAD THERE BEEN A SPARK FROM A LIGHT SWITCH OR SOME OTHER IGNITER. AFTER VENTILATING THE GARAGE I SEARCHED FOR THE SOURCE AND FOR THE FIRST TIME SAW A SMALL GASOLINE LEAK ON THE FLOOR OF THE GARAGE UNDER MY 2004 CORVETTE. I IMMEDIATELY SEARCHED ONLINE AND FOUND THAT HUNDREDS OF COMPLAINTS FOR A SIMILAR PROBLEM HAD BEEN ADDRESSED BY THE NHTSA AND CHEVROLET, SO I TOOK IT TO MY DEALER, WHO VERIFIED I HAD THE SAME PROBLEM AND THEY REPLACED THE LEFT FUEL TANK AND CROSSOVER PIPE. THE COST FOR PARTS, LABOR AND TAX WAS $3,676 AND THE DEALER SAYS THAT THE REPAIR FOR THIS KNOWN MANUFACTURING DEFECT IS OUTSIDE THE EXTENDED WARRANTY THAT CHEVROLET AGREED TO, AS NOTED IN NHTSA ACTION #: PE10015. I NEVER RECEIVED NOTIFICATION OF THE PROBLEM IN 2010 OR I WOULD HAVE HAD CHEVROLET SERVICE CHECK THE VEHICLE FOR THE PROBLEM AT THAT TIME. I AM CURRENTLY IN THE PROCESS OF CONTACTING CHEVROLET CUSTOMER SERVICE, SEEKING REIMBURSEMENT OF ALL COSTS ASSOCIATED WITH THIS REPAIR.

Mileage: 60,000

AFTER A RECENT FILL UP, I SMELLED FUEL IN MY GARAGE AFTER PARKING MY 2004 CHEVROLET CORVETTE FOR SEVERAL HOURS. I CHECKED ONLINE, AND DISCOVERED THAT MY CAR FALLS WITHIN THE VIN RANGE FOR THE SPECIAL COVERAGE ADJUSTMENT (#10150) ISSUED IN 2010. I TOOK THE CAR TO A LOCAL CHEVROLET DEALERSHIP WHERE IT WAS DIAGNOSED AS A CRACKED FUEL TANK AT THE QUICK CONNECTOR. UNFORTUNATELY, THE 10-YEAR LIMIT HAS EXPIRED. MY VEHICLE HAS JUST OVER 40,000 MILES SO THE 100,000 MILE LIMIT HASN'T BEEN REACHED. THE CHEVROLET DEALERSHIP WON'T REPLACE IT BECAUSE THE TIME LIMIT IS UP. SO FAR, GENERAL MOTORS HASN'T OFFERED TO REPLACE IT EITHER. THEY'LL ONLY CONTACT THE DEALER TO ATTEMPT TO WORK OUT A MORE FAVORABLE DEAL. THE QUOTE I RECEIVED FOR REPAIR WAS $3,472. THIS IS AN EXTREMELY SERIOUS SAFETY ISSUE AND A KNOWN DEFECT, BUT GM WILL NOT ADDRESS IT PROPERLY. THEY'LL OFFER FREE REPLACEMENT TO OTHER VEHICLES WITH FUEL LEAKS (06-09 COBALTS) REGARDLESS OF MILEAGE OR TIME, BUT NOT THEIR FLAGSHIP AUTOMOBILE. I WOULD LIKE THE NHTSA TO REEXAMINE THIS VERY DANGEROUS SITUATION.

Mileage: 40,000

TL* THE CONTACT OWNS A 2004 CHEVROLET CORVETTE. THE CONTACT NOTICED A STRONG ODOR OF FUEL WHEN THE TANK WAS FULL. THE DEALER DIAGNOSED THAT THE DRIVER SIDE FUEL TANK CONNECTOR WAS LEAKING. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 32,500. *BF UPDATED 10/17/2017*CN

Mileage: 32,500

2004 CHEVY Z06 CORVETTE HAS A FUEL LEAK ON TOP OF THE DRIVER SIDE ABOVE THE FUEL TANK COMING FROM THE CROSS OVER TUBE. THE PLASTIC COUPLER HAS O-RING THAT I THINKS HAS FAILED. I JACKED THE CAR UP ON MY OWN TOOK A BORE SCOPE UP THE COUPLER AND IT WAS COVER IN FUEL. THIS VEHICLE HAS NO TROUBLE CODES IN THE COMPUTER SYSTEM. I USED A SNAP-ON MODIS SCAN TOOL TO DO A FULL SWEEP OF THE VEHICLE. THE MIL IS NOT ON, I THINK THERE SHOULD A EVAP LIGHT SAYING THAT HYDROCARBONS ARE ESCAPING FROM THE FUEL SYSTEM. LOOKING ON LINE THERE IS A LOT OF COMPLAINS ABOUT C5 CORVETTE HAVING THIS ISSUE. THEREFORE BEING AN AUTOMOTIVE REPAIR TECHNICIAN SERVICING CARS FOR A LIVING I FEEL ACTION SHOULD BE TAKING FOR THE SAFETY OF THE CONSUMER, AND THE ENVIRONMENT KNOW THAT FUEL VAPORS ARE ESCAPING INTO THE ATMOSPHERE. PLUS WITH FUEL LEAKING AROUND THE GAS TANK AND THE EXHAUST SYSTEM RUNNING AN INCH AND HALF AWAY FROM IT THERE IS A POTENTIAL OF HAVING A FIRE HAPPEN TO SOMEONE VALUABLE CORVETTE. THE WAS A FUEL ODOR LONG BEFORE THE FUEL CROSS OVER TUBE STARTING LEAK. AT THAT POINT THE GAS CAP ON MY CAR HAD FAIL TO I REPLACE THAT THE FUEL CAP FUEL SMELL WENT AWAY. USING MY SNAP -ON MODIS, I WAS ABLE TO TEST THE EVAP SYSTEM AND PURGE IT WITH ANY TROUBLE CODES ON OR MIL LIGHT BEING ON OR ANY ISSUES WHAT SO EVER. WITH THE GAS CAP FAILING THERE SHOULD HAVE BEEN A PO440 CODE STATING A LARGE EVAP FAILURE CODE. IN THIS CASE THERE WAS NOTHING I CALL MY LOCAL GENERAL MOTORS DEALERSHIP THEY SAID, THERE SHOULD BE A CODE TO LOOSE GAS CAP. I SAID, THERE WAS NOTHING AND DEALERSHIP WAS SHOCKED. I THANK YOU FOR TAKING THE TIME TO READ MY COMPLAIN AND HOPE APPROPRIATE ACTIONS TO RENDER IS ISSUE ON C5 MODEL CORVETTE. *TR

Mileage: 57,880

ENGINE LIGHT CAME ON, TOOK TO MECHANIC, FUEL VAPOR/FUEL LEAK IDENTIFIED, SMOKE TEST PERFORMED, SOURCE APPEARS TO BE TANK/TANK STRAPS. *TR

Mileage: 24,900

I FILL UP THE FUEL TANK. GOT HOME AND SMELLED GAS REAL BAD. LEAKING UNDER LEFT TANK. I CALLED DEALERSHIP.THEY WILL NOT DO ANYTHING. THEY SAID TO CALL GM. I CALLED THEY WILL NOT DO NOTHING. I HAVE OWN GM ALL MY LIFE . I WILL NOT BUY A GM NO MORE, THANKS *TR

Mileage: 13,058

DRIVING A 2004 CHEVROLET CORVETTE AT 65 MPH AND ENGINE SHUT DOWN,LUCKILY ABLE TO COAST TO SIDE OF HIGHWAY WITHOUT AN ACCIDENT. I HAD CAR TOWED TO LOCAL CHEVROLET DEALER-WHERE VEHICLE WAS PURCHASED 19 MONTHS PRIOR) DEALER STATED THAT FUEL PUMP INOPERATIVE AND REQUIRED REPLACEMENT..THE TWO FUEL PUMPS( REGULAR FUEL PUMP AND SIPHON FUEL PUMP) LOCATED IN FUEL TANKS ,WERE REPLACED AND ALL TANKS AND MUFFLER WERE RE-INSTALLED.THE FUEL PUMPS WERE NOT OPERATING ,SO THE FUEL TANKS WERE REMOVED AGAIN, AND A RELAY WAS FOUND TO BE DEFECTIVE,FINGERS ON RELAY WERE CURLED UP AND NOT ALLOWING FUEL PUMPS TO RUN. THE COST OF REPLACING FUEL PUMPS WAS CHARGED TO ME AT $2700,HOWEVER THE COST OF REPLACING THE RELAY AND ALL PARTS REMOVED TO REPLACE RELAY, WAS CHARGED TO CHEVROLET FOR A DEFECTIVE RELAY.THE VEHICLE WAS PICKED UP FROM DEALER BY ME ON 9/18/2014;THEN RETURNED 9/19/2014 AS GAS VAPORS WERE DETECTED BY ME INSIDE VEHICLE AND IN MY GARAGE. DEALER CURRENTLY HAS VEHICLE-9/21/2014...UPDATED 10/22/14*BF UPDATED 4/7/2015*JS *TR

Mileage: 21,300

TL* THE CONTACT OWNS A 2004 CHEVROLET CORVETTE. THE CONTACT STATED THE FUEL WAS LEAKING FROM THE FUEL TANK DUE TO A FRACTURE ON THE INSIDE. THE CONTACT TOOK THE VEHICLE TO A MECHANIC WHO CONFIRMED THE CRACK IN THE TANK AND THAT THE LEAK WAS COMING FROM THE FILLER NECK. THE FAILURE MILEAGE WAS UNKNOWN. THE CURRENT MILEAGE WAS 105,500.

DRIVING 65 MPH ON INTERSTATE 90 WISCONSIN. CAR JUST DIED,COULD NOT GET TO RESTART. 1 HOUR ON THE SIDE THE ROAD. CARS FLYING INCHES FROM US. POLICE OFFICER FINALLY STOPED AND CALLED TOW TRUCK AND STAYED BEHIND US WITH LIGHTS ON SO WE WOULDNT GET HIT. TO FIND OUT THIS IS A COMMON PROBLEM ON LOW MILAGE CORVETTES. SHOULD BE A RECALL BECAUSE THE CHEVY DEALER IN MIDDELTON WIS DIDNT KNOW WHAT WAS WRONG, IT KEEPS ON BLOWING THE FUEL PUMP FUSE.THEY THINK,BUT NOT SURE ITS THE FUEL PUMP. 2500.00 TO FIX. CORVETTE FORUM STATES THIS IS A COMMON PROBLEM. THIS IS A SAFETY ISSUE I WOULLD THINK. *TR

Mileage: 23,312