2004 CHEVROLET CORVETTE Fuel System, Gasoline Problems

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.

Mileage: 44,000

The contact owns a 2004 Chevrolet Corvette. The contact stated while driving at slow speeds and approaching a stop, an abnormal odor of fuel was detected. The contact noticed there was fuel leaking in the garage. The vehicle was taken to the local dealer where it was diagnosed that the fuel tank and crossover tube cross connector needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure but no additional assistance was provided. The contact stated the failure was related to NHTSA Action Number: PE10015 (Fuel System, Gasoline). The approximate failure mileage was 41,000. The contact stated that the vehicle was repaired and is seeking reimbursement from the manufacturer for the cost.

Mileage: 41,000

THE CONTACT OWNS A 2004 CHEVROLET CORVETTE. THE CONTACT STATED WHILE DRIVING 35 MPH, THE CONTACT SMELLED AN ABNORMAL FUEL ODOR COMING FROM THE ENGINE COMPARTMENT. THERE WAS NO WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TOWED TO THE LOCAL DEALER TO BE DIAGNOSED. THE CONTACT WAS INFORMED THAT THE FUEL TANK CROSSOVER PIPE NEEDED TO BE REPLACED. THE VEHICLE WAS NOT YET REPAIRED. THE CONTACT RELATED THE ISSUE TO AN UNKNOWN MANUFACTURER’S RECALL. THE MANUFACTURER WAS INFORMED OF THE FAILURE BUT OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 36,000.

Mileage: 36,000

SINCE BUYING THIS CAR AT AUCTION. I NOTICED A FUEL SMELL COMING FROM LEFT REAR WHEELS. I HAVE ASKED THE DEALERSHIP IF THERE WERE ANY RECALLS OR SPECIALS ANNOUNCEMENTS DEALING WITH CAR AND WAS TOLD NO. AFTER READING THE CORVETTE FORUM AND FINDING THERE WAS A REPAIR FOR THE FUEL TANK. NOW MY CAR IS OUT OF THE COVERAGE TIME FRAME AND MILEAGE HOWEVER WITH THE TANK BEING DEFECTIVE SHOULDN'T THEY AT LEAST COVER THE TANK. OR WHAT WAS THE AGREEMENT BETWEEN NHTSA AND CHEVROLET. *TR

Mileage: 106,765

I FILLED MY TANK TODAY WITH NO OVER FLOW OF GAS. I GOT IN MY VEHICLE AND STARTED THE CAR. I NOW HAVE A VERY STRONG GASOLINE SMELL. IT IS ALL THROUGHOUT THE CABIN AND MAKE GAS APPEARS TO BE RUNNING OUT FASTER THAN NORMAL. I PARK IN A GARAGE WHICH HAS A GAS WATER HEATER IN IT. I AM VERY CONCERNED THAT THE HOUSE COULD CATCH ON FIRE IF THE LEAK GETS STRONGER. *TR

Mileage: 67,430

LEAKING GAS. MECHANIC SAYS GAS TANK IS LEAKING NEEDS REPLACED. SEEMS TO BE A PROBLEM WITH THIS CAR YET THERE IS NO RECALL? *TR

Mileage: 120,000

NOTICED GAS LEAKING ON GROUND AFTER REFUELING THE CAR....I DON'T DRIVE THE CAR MUCH AND SINCE THEN THERE IS ALWAYS A STRONG SMELL OF GAS. THE CAR NOW HAS 39850 MILES ON IT AND THE SMELL IS GETTING WORSE. *TR

Mileage: 35,698

WHEN I WAS FILLING UP MY CAR AT A GAS STATION I NOTICED A RATHER STRONG SMELL OF GAS. I LOOKED UNDER THE CAR TO SEE THAT IT WAS LEAKING FUEL. I FINISHED THE CAR TRIP AND TOOK IT TO THE DEALER. THEY SAID THE GAS TANK WAS LEAKING AND NEEDED TO BE REPLACED. *TR

Mileage: 127,000

I AM EXPERIENCING STRONG ODORS OF GASOLINE, FAINT AT FIRST, BUT NOW VERY EVIDENT AROUND THE VEHICLE AND IN THE DRIVER'S COMPARTMENT. I AM QUITE CONCERNED TO PLACE THE CAR IN THE GARAGE, OR EVEN DRIVE IT. CHECKING ON LINE, I FOUND A DEPARTMENT INVESTIGATION, BUT NOTHING ON A RECALL. THE COMPLAINT WAS PREVALENTLY POSTED ON FORUMS WITH THE MOST COMMON SOURCE AS THE GAS TANK AND/OR CROSSOVER PIPE. DEALERS SEEM TO BE USING THE OPPORTUNITY OF FEAR OF A FIRE FOR OVERCHARGING (~$2500) FOR A REPAIR THAT SHOULD BE A RECALL. WOULD YOU PLEASE ADVISE WITH MY OPTIONS. *TR

Mileage: 25,500

FUEL LEAK. I 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. *TR

Mileage: 40,000

STRONG GAS FUME'S WHEN TANK IS HALF FULL. *TR

Mileage: 34,000

DRIVERS SIDE GAS TANK HAS A LEAK NITA'S HAS OPEN INVESTIGATION ON THIS COMPLAINT. *TR

Mileage: 55,000

VEHICLE CUT OFF WHILE DRIVING @ APPROXIMATELY 25 MPH. DASH INDICATOR READ "CHECK GAUGES". I WAS ABLE TO PULL TO THE SIDE OF THE ROAD AND FOUND THAT THE FUEL PUMP FUSE HAD FAILED. TRIED ANOTHER FUSE, BUT IT BLEW IMMEDIATELY. VEHICLE WAS TOWED TO LOCAL CHEVROLET DEALER WHO HAS DIAGNOSED PROBLEM AS BOTH FUEL PUMPS HAVE SHORTS CAUSING THE FUEL PUMP FUSE TO BLOW. THIS IS A VERY DANGEROUS SITUATION AND NEEDS TO BE INVESTIGATED. IT SHOULD BE NOTED THAT AFTER A DAY OF SITTING AT THE DEALERSHIP, THE FUEL PUMP FUSE WAS REPLACED AND THE VEHICLE THEN STARTED ENABLING THE DEALER TO DIAGNOSE THE PROBLEM. CHEVROLET ZONE REP WAS CONTACTED, BUT REFUSED TO HELP. THERE IS OBVIOUSLY AN ISSUE WITH THE FUEL PUMPS AS THE REPLACEMENT FUEL PUMPS FROM CHEVROLET HAVE BEEN REDESIGNED. IT SHOULD BE NOTED THAT VEHICLE HAS ONLY 18,316 MILES. *KB

VEHICLE CUT OFF WHILE DRIVING @ APPROXIMATELY 25 MPH. DASH INDICATOR READ "CHECK GAUGES". I WAS ABLE TO PULL TO THE SIDE OF THE ROAD AND FOUND THAT THE FUEL PUMP FUSE HAD FAILED. TRIED ANOTHER FUSE, BUT IT BLEW IMMEDIATELY. VEHICLE WAS TOWED TO LOCAL CHEVROLET DEALER WHO HAS DIAGNOSED PROBLEM AS BOTH FUEL PUMPS HAVE SHORTS CAUSING THE FUEL PUMP FUSE TO BLOW. THIS IS A VERY DANGEROUS SITUATION AND NEEDS TO BE INVESTIGATED. IT SHOULD BE NOTED THAT AFTER A DAY OF SITTING AT THE DEALERSHIP, THE FUEL PUMP FUSE WAS REPLACED AND THE VEHICLE THEN STARTED ENABLING THE DEALER TO DIAGNOSE THE PROBLEM. CHEVROLET ZONE REP WAS CONTACTED, BUT REFUSED TO HELP. THERE IS OBVIOUSLY AN ISSUE WITH THE FUEL PUMPS AS THE REPLACEMENT FUEL PUMPS FROM CHEVROLET HAVE BEEN REDESIGNED. IT SHOULD BE NOTED THAT VEHICLE HAS ONLY 18,316 MILES. *KB

I HAVE RECENTLY BEEN TOLD BY REPRESENTATIVES OF YOUNG CHEVY DEALERSHIP IN DALLAS, TEXAS THAT I HAVE A GASOLINE FUEL LEAK AT THE CONNECTOR OF THE TWO GAS TANKS. IN MY OPINION THIS IS A "LIFE-SAFETY" ISSUE THAT MUST BE ADDRESSED BY GENERAL MOTORS (GM) IMMEDIATELY. I LOVE MY 2004 CORVETTE AND PLAN ON CONTINUING TO DRIVE IT DAILY UNTIL IT IS PROPERLY "FIXED" AT NO COST TO ME, OR I DIE DRIVING IT BECAUSE IT WAS AN UNSAFE CONDITION CAUSED BY GM AND NOT ADDRESSED WITHIN A TOTAL RECALL OF THE DEFECTIVE ASSEMBLY. I WILL GLADLY JOIN A CLASS-ACTION LAWSUIT FOR THIS UN-SAFE CONDITION CREATED BY GM.

Mileage: 182,000

I OWN A 2004 CHEVROLET CORVETTE. WHILE THE VEHICLE WAS PARKED IN THE GARAGE I SMELLED A STRONG FUEL ODOR. I CHECKED AND HE REPLACED THE GASOLINE CAP, AND NOTICED A GAS PUDDLE ON THE GROUND WASHED THE VEHICLE BUT COULD STILL SMELL FUEL. THE VEHICLE WAS TAKEN TO A CHEVROLET MECHANIC WHO DIAGNOSED THE FAILURE AND CONFIRMED THAT THE FUEL TANK PIPE CONNECTORS WERE DEFECTIVE. THE FUEL TANK CONNECTORS COULD NOT BE REPLACED; THEREFORE, THE FUEL TANK HAD TO BE REPLACED. THE VEHICLE WASN'T REPAIRED. THE FAILURE MILEAGE WAS 35,400 AND THE CURRENT MILEAGE WAS 35,400. THE CHEVROLET DEALER DIAGNOSED THE FOLLOWING ISSUES: NEEDS LEFT SIDE FUEL TANK AND SENDING UNIT $3,887.50, REAR BRAKES PADS AND ROTORS $517.50, FRONT BRAKES PADS AND ROTORS $482.50, BRAKE FLUSH $165.00, INDUCTION AND INJECTOR SERVICES $350.00. SERVICE REAR POSI DIFF. $165.00. CURRENTLY I AM A CANCER PATIENT AND DUE TO MEDICAL COST I AM UNABLE TO AFFORD THE REPAIRS. THIS VEHICLE IS THE ONLY MODE OF TRANSPORTATION THAT I HAVE.ANY ASSISTANCE THAT YOU COULD AFFORD ME WOULD BE GREATLY APPRECIATED SHOULDN'T THE ISSUES BE A RECALL/SAFETY ISSUE. THANKS IN ADVANCE..R. THOMAS

Mileage: 35,400

STRONG GASOLINE ODOR INSIDE THE VEHICLE AFTER FILLUP AND WHEN PARKED IN GARAGE THAT STARTED AROUND 05/15/2010. I REPLACED THE GAS CAP AND THAT DID NOT HELP. I HAD MECHANIC LOOK AT IT AND SAID IT SEEMS TO BE A CRACKED FUEL TANK OR CROSSOVER PIPE LEAK . DRIVE-TRAIN MUST BE DROP TO VERIFY AND COST TO REPAIR UPWARDS AROUND $2K-$3K . AFTER A INTERNET SEARCH THIS IS A KNOW COMMON PROBLEM FOR THIS YEAR CORVETTE. THIS SHOULD BE A MANUFACTURER RECALL! *TR

Mileage: 105,000

SMELL OF GAS NOTICEABLE WHEN CAR JUST SITTING IN GARAGE. SERVICE ENGINE LIGHT ALSO CAME ON. VEHICLE BROUGHT IN FOR SERVICE AND FOUND TO HAVE RIGHT FUEL TANK LEAK. (OF IMPORTANCE WAS THE FACT WE HAD THE LEFT GAS TANK REPLACED ABOUT A YEAR BEFORE THIS EVENT AT WHICH TIME I THOUGHT IT WAS JUST A FREAK OCCURRENCE UNTIL IT HAPPENED AGAIN)

Mileage: 48,555

STRONG GAS SMELL BEHIND DRIVER'S SEAT.

I HAVE A 2004 CHEVROLET CORVETTE THAT IS LEAKING GAS. MECHANIC SAID IT IS THE "FUEL TANK CROSSOVER". AFTER MUCH RESEARCHING, I HAVE FOUND THAT THIS IS A BIG PROBLEM FOR THIS YEAR. COST WILL BE OVER $2,000 TO REPAIR. THIS SHOULD BE A RECALL! SOME OF THESE CORVETTES HAVE CAUGHT FIRE. *TR

Mileage: 22,373

2004 CORVETTE OWNER. WHEN I PARK MY CAR IN THE GARAGE THERE IS A STRONG FUEL SMELL. I TOOK THE CAR TO THE MANUFACTURER AND THEY TOLD ME THAT THEY HAVE HAD MULTITUDES OF ISSUES WITH OWNERS WHO HAVE 2004 CORVETTES ON THE FUEL SYSTEM, ESPECIALLY PERTAINING TO THE GAS TANK. THE CROSSOVER LEAKS. *TR

TL*THE CONTACT OWNED A 2004 CHEVROLET CORVETTE. WHILE THE VEHICLE WAS PARKED, THE CONTACT NOTICED A PUDDLE OF GASOLINE ON THE DRIVER SIDE BESIDE THE REAR TIRE. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR DIAGNOSIS OR REPAIR. THE APPROXIMATE FAILURE MILEAGE WAS 34,000.

Mileage: 34,000

2004 CORVETTE Z06 LEAKS FUEL UNDER THE VEHICLE AND VERY LIKELY INTO THE PASSENGER COMPARTMENT JUDGING BY THE SMELL. CAR HAS 18,XXX MILES ON IT, COMPLETELY STOCK AND NEVER ABUSED. WHEN FILLING THE FUEL ENDS UP POOLED UNDER REAR DRIVER TIRE AREA. SMELL INSIDE IS VERY STRONG OF RAW GASOLINE. SMELL REMAINS FOR DAYS IF PARKED, AND SMALL PUDDLE FOUND UNDER THE LEFT FUEL TANK. THIS VEHICLE IS IN ALMOST BRAND NEW CONDITION. *TR

HAD TO HAVE THE GAS TANK REPLACED ON MY 2004 CHEVROLET CORVETTE CONVERTIBLE AT A COST OF $2600 IN SEPTEMBER OF 2009. HAVE SINCE LEARNED THAT NHTSA IS INVESTIGATING THIS. PLEASE ADD THIS TO THE LIST. *TR

Mileage: 23,816

PROBLEM 1: GASOLINE SMELL WITH LEAK AND ULTIMATE FAILURE OF VALVE TO TRANSFER FUEL FROM ONE TANK TO ANOTHER. OCCURRED CONTINUALLY WITH FUEL TANK REGISTERING FULL TO 3/4 TANK THEN DROPPING TO EMPTY AND VEHICLE APPEARED TO BE OUT OF GAS (WOULD NOT RUN UNTIL FUEL ADDED TO TANK). SOLUTION: TOOK VEHICLE TO CHEVROLET DEALERSHIP FOR REPAIRS. REPAIR INVOICE STATES: "REPLACED L/S GAS TANK AND PUMP AND SENDER AND REPLACED R/S FUEL PUMP AND SENDER. CHECK FUEL GAUGE AND TANKS FOUND L/S FUEL TANK LEAKING AT TOP OF TANK. WELD ALSO FOUND FUEL LEVEL SENSORS OPEN CIRCUIT AND FUEL SYSTEM NOT TRANSFERRING FUEL FROM TANK TO TANK. RETEST AFTER REPAIRS. OK" PROBLEM 2: A/C DISPLAY LIGHTS DO NOT ILLUMINATE AND CONTROLS ARE DIFFICULT TO SEE AT NIGHT. SOLUTION: TOOK TO CHEVROLET DEALERSHIP FOR REPAIRS. REPAIR INVOICE STATES: "CONTROLLER HAS INTERNAL FAILURE, REPLACED CONTROLLER." *TR

Mileage: 130,000

2004 CHEVROLET CORVETTE: THIS PROBLEM BECAME EVIDENT AFTER A STRONG GASOLINE ODOR AND GASOLINE VAPORS BEGAN TO BE NOTICEABLE IN THE PASSENGER CABIN. NOW GAS HAS BEEN DETECTED LEAKING FROM UNDER DRIVER SIDE SEAT. AFTER RESEARCHING THE ISSUE ON THE INTERNET IT IS CLEAR THIS IS WIDE SPREAD PROBLEM WITH THE POSSIBILITY OF FIRE AND OR ENVIRONMENTAL DAMAGE. THE CAR WAS PURCHASED USED ONE YEAR AGO. NOTHING HAS BEEN DONE YET TO CORRECT THE PROBLEM DUE TO LACK OF FUNDS TO HAVE THE DEALER ADDRESS THE ISSUE. MOST INFORMATION I HAVE SEEN PLACE THE REPAIR AT AROUND $2,000.00. *TR

Mileage: 41,000

TL*THE CONTACT OWNS A 2004 CHEVROLET CORVETTE. WHILE THE VEHICLE WAS PARKED IN THE GARAGE THE CONTACT SMELLED A STRONG FUEL ODOR. HE REPLACED THE GASOLINE CAP, WASHED THE VEHICLE BUT COULD STILL SMELL FUEL. THE VEHICLE WAS TAKEN TO A MECHANIC WHO DIAGNOSED THE FAILURE AND CONFIRMED THAT THE FUEL TANK PIPE CONNECTORS WERE DEFECTIVE. THE FUEL TANK CONNECTORS COULD NOT BE REPLACED; THEREFORE, THE FUEL TANK HAD TO BE REPLACED. THE VEHICLE WASN'T REPAIRED. THE FAILURE MILEAGE WAS 35,400 AND THE CURRENT MILEAGE WAS 36,100.

Mileage: 35,400

2004 CHEVROLET CORVETTE BEGAN LEAKING FUEL AFTER 5K MILES. DEALER SAID IT WAS A FAULTY FUEL TANK AND CROSSOVER TUBE BETWEEN THE TWO PARTS OF THE TANK. $1400 TO REPLACE FUEL TANK. THE CAR COULD HAVE BURNED TO THE GROUND, THERE WAS FUEL RUNNING EVERYWHERE AT THE GAS STATION! *TR

Mileage: 5,000

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

Mileage: 58,000

04 CORVETTE ZO6 LEAKING FUEL WHEN I FILLED IT. I HAVE BEEN SMELLING FUEL FOR A WHILE NOW AND I GUESS THIS WHY. IT SEEMS WHEN I WAS ALMOST DONE FILLING IT UP IT STARTED DRIPPING FUEL ON THE GROUND IN FRONT OF THE L/R TIRE. TOOK IT TO DEALER NO RESULTS YET. *TR

Mileage: 76,100

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

Mileage: 29,000

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

Mileage: 21,582

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

Mileage: 63,000

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.

Mileage: 12,900

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

Mileage: 42,300

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

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

Mileage: 9,450

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

Mileage: 28,533

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

Mileage: 40,600

A 2004 CORVETTE COUP DEVELOPED A STRONG GASOLINE SMELL AND LEAKS ON THE DRIVER SIDE WHEN THE FUEL TANK IS ALMOST FULL. MILEAGE IS 45,836. REPLACED GAS CAP TO REDUCE GAS SMELL WITH NO IMPROVEMENT THEN NOTICED LEAK DURING REFUELING. *TR

Mileage: 45,830

TL* THE CONTACT OWNS A 2004 CHEVROLET CORVETTE. THE CONTACT STATED THE VEHICLE WAS PARKED IN A RESIDENTIAL GARAGE WHEN THE CONTACT NOTICED THERE WAS A STRONG, OVERPOWERING GASOLINE ODOR FROM THE VEHICLE. THE CONTACT HAD RECENTLY REFUELED THE VEHICLE AND FOUND A LARGE, ABNORMAL PUDDLE OF GASOLINE UNDER THE VEHICLE. THE DEALER ADVISED THAT THE DRIVE SIDE FUEL TANK HAD FRACTURED AND WAS LEAKING. THE DEALER REPLACED THE FUEL TANK. THE FAILURE DID NOT RECUR. THE FAILURE MILEAGE WAS 43,617 AND THE CURRENT MILEAGE WAS 43,968.

Mileage: 43,617

EACH TIME I FILL THE GAS TANK THERE IS A STRONG GAS ODOR UNTIL THE FUEL LEVEL IS BELOW HALF A TANK AND THEN THE ODOR OF GAS IS NONEXISTENT. THE DRIVERS SIDE OF THE CAR HAS A STRONGER ODOR OF GAS WHEN PRESENT. *TR

Mileage: 96,000

TL*THE CONTACT OWNS A 2004 CHEVROLET CORVETTE. THE CONTACT STATED THAT THEY BEGAN TO SMELL GASOLINE COMING FROM THE VEHICLE. THE FUEL TANK WAS REPLACED. THE DEALER STATED THAT THE FUEL WAS LEAKING FROM THE TANK AND THAT SINCE THERE WAS A NHTSA INVESTIGATION, THEY WERE UNABLE TO DISCUSS THE SPECIFICS. NHTSA INVESTIGATION PE10015 WAS OPENED ON 5/12/2010. THE CONTACT HAD THE TANK, PADS AND INSULATOR REPLACED ON THE VEHICLE. THE FAILURE MILEAGE WAS 68805 AND THE CURRENT MILEAGE WAS 68900.

Mileage: 68,805

LEFT SIDE FUEL TANK LEAKING GAS. *TR

Mileage: 29,331

SMELL OF GASOLINE WHEN STOPPED AND AFTER CAR IS PARKED OVERNIGHT. UPDATED 08/04/10 *BF THE CONSUMER NOTIFIED THE ESTABLISHMENT WHERE THE VEHICLE WAS PURCHASED. AFTER INSPECTING THE FUEL TANK, THEY FOUND A WET AREA WITH FUEL ON THE TOP AND SIDE OF THE LEFT FUEL TANK. THEY REPLACED AN O-RING SEAL ON THE LEFT OF THE FUEL TANK CROSS-OVER TUBE. THE PROBLEM WAS NOT RESOLVED. UPDATED IVOQ 08/05/10 *TR

Mileage: 45,000

FUEL TANK IS LEAKING VAPORS AND FUEL. 1. THERE ARE NO SPECIFIC EVENTS LEADING UP TO FAILURE 2. FAILURE IS CONTINUOUS 3. NOTHING HAS BEEN DONE TO CORRECT. FIRST NOTICED ON OR ABOUT JUNE 1, 2010. *TR

Mileage: 57,500

I OWN A 2004 CHEVY CORVETTE AND GASOLINE AND FUEL VAPORS ARE LEAKING FROM MY CAR. ONE OF MY TWO GAS TANK IS THE SOURCE OF THE LEAK AND IT NEEDS TO BE REPLACED. AFTER TAKING IT TO GEARHART CHEVROLET ON ROUTE 46 IN DENVILLE NJ, THEY EXPLAINED THAT THE ENTIRE TANK NEEDS TO BE REPLACE AND IT WILL COST OVER $2,000 FOR PARTS AND LABOR. I HAVE NOTICED THAT THERE WERE MANY COMPLAINTS ABOUT THIS ISSUE WITH THE 2004 CORVETTE AND WANT TO KNOW IF THE ISSUE HAS CAUSE A RECALL. *TR

Mileage: 40,000

TL* THE CONTACT OWNS A 2004 CHEVROLET CORVETTE. THE CONTACT STATED THERE WAS AN OVERWHELMING ODOR OF GASOLINE IN THE VEHICLE. HE REPLACED THE FUEL CAP BUT CONTINUED TO SMELL THE ODOR. THE VEHICLE WAS TAKEN FOR STATE INSPECTION AND DID NOT PASS DUE TO A GAS LEAK BEING FOUND AT THE REAR DRIVER SIDE TIRE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT CONTACTED. THE VIN WAS NOT AVAILABLE. THE FAILURE AND THE CURRENT MILEAGES WERE 100,000.

Mileage: 100,000

TL*THE CONTACT OWNS A 2004 CHEVROLET CORVETTE. HE NOTICED A GASOLINE ODOR AFTER HE REPLACED THE GASOLINE CAP, BUT THE ODOR REMAINED. THE VEHICLE FAILED THE STATED INSPECTION, DUE TO A GAS LEAK THAT WAS LOCATED NEAR THE REAR LEFT TIRE. THE MANUFACTURER WILL BE CONTACTED. THE VIN WAS NOT AVAILABLE. THE FAILURE AND THE CURRENT MILEAGES WERE 100,000.

Mileage: 100,000

FUEL LEAK ON 2004 CHEVROLET CORVETTE. STRONG GASOLINE ODOR INSIDE THE VEHICLE. TANK LEAKAGE IF FILLED FOR $20 OR MORE OF GASOLINE. *TR

Mileage: 13,626

EACH TIME I FILLED THE GAS TANK THERE IS A GAS ODOR. THE PASSENGER SIDE TANK ON MY 2004 CORVETTE SHOWED SIGNS THAT GAS HAD BEEN LEAKING FROM THE TOP. AFTER DRIVING A WHILE THE ODOR AND LEAK STOPPED. REPLACING THE TANK WAS THE ONLY WAY OF CORRECTING THE PROBLEM AND AVOIDING A FIRE. *TR

Mileage: 11,900

I OWN A 2004 CHEVROLET CORVETTE CONVERTIBLE AND IT HAS A STRONG FUEL SMELL WHEN I DRIVE IT - THE SMELL EMANATES INSIDE THE VEHICLE. *TR

TL* THE CONTACT OWNS A 2004 CHEVROLET CORVETTE. WHILE THE VEHICLE WAS PARKED, THE CONTACTED NOTICED AN UNUSUALLY OVERPOWERING GASOLINE ODOR. THE DEALER PERFORMED A DIAGNOSTIC AND DISCOVERED THAT THE LEFT FUEL TANK WAS LEAKING BUT HE WAS UNABLE TO DETERMINE THE EXACT LOCATION OF THE FAILURE. THE MANUFACTURER WAS CONTACTED AND ADVISED THEY WOULD RETURN HIS CALL LATER TO DETERMINE IF THEY WOULD ASSIST WITH REPAIRS. THE FAILURE AND THE CURRENT MILEAGES WERE 33,000.

Mileage: 33,000

NOTICED PUDDLE OF FUEL UNDER CAR AFT OF DRIVER DOOR. TOOK TO DEALER WHO REPLACED CROSSOVER PIPE WHICH THEY SAID WAS CRACKED. UNDER ORIGINAL WARRANTY. *TR

Mileage: 20,000

STRONG SMELL OF FUEL AND OCCASIONAL DRIPPING OF GAS. I AM ON VACATION IN ILLINOIS FROM ARIZONA AND AM NOW FACING A $1500 BILL JUST TO GET BACK HOME. I SEE GM DOESN'T CARE SO MAYBE FORD WOULD LIKE A VETTE. *TR

Mileage: 52,000

THE GAS TANK IS LEAKING ON MY 2004 CORVETTE. *TR

TL* THE CONTACT OWNS A 2004 CHEVROLET CORVETTE. THE FUEL TANK WAS LEAKING CAUSING A SMALL FIRE ON THE GROUND BUT THERE WAS NO DAMAGE TO THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THEY STATED THERE WAS A SMALL CRACK IN THE FUEL TANK AND IT WOULD NEED TO BE REPLACED, AT HIS EXPENSE. THERE WERE NO RECALLS FOR THE FAILURE. THE FAILURE MILEAGE WAS 23,000. UPDATED 06/21/10 *BF RECEIVED PICTURES. UPDATED 09/27/10*JB UPDATED 12/01/10. *LJ GM PROVIDED 50% OF THE INITIAL COST AND LATER THE OTHER 50%. UPDATED 12/07/10

Mileage: 23,000

INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6) OWN A 2004 CORVETTE THAT HAS BEEN LEAKING FUEL AND VAPORS. TOOK IT IN FOR SERVICE AND WAS TOLD THAT I NEED A NEW FUEL TANK. WE ONLY HAVE APPROX. 5200 MILES. CURRENTLY BEING WORKED ON AT SCHUMACHER CHEVROLET 8 MAIN ST, LITTLE FALLS, NJ 07424 973-256-1065. WE TOLD THEM WE WERE GOING TO WRITE TO YOU AND TO KEEP ALL THE PARTS FOR INVESTIGATION. PLEASE LOOK INTO TO THIS FOR US. [XXX] *TR UPDATED 06/24/10 *BF RECEIVED PHOTOS. UPDATED 06/25/10.*JB

Mileage: 5,200

INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6) OWN A 2004 CORVETTE THAT HAS BEEN LEAKING FUEL AND VAPORS. TOOK IT IN FOR SERVICE AND WAS TOLD THAT I NEED A NEW FUEL TANK. WE ONLY HAVE APPROX. 5200 MILES. CURRENTLY BEING WORKED ON AT SCHUMACHER CHEVROLET 8 MAIN ST, LITTLE FALLS, NJ 07424 973-256-1065. WE TOLD THEM WE WERE GOING TO WRITE TO YOU AND TO KEEP ALL THE PARTS FOR INVESTIGATION. PLEASE LOOK INTO TO THIS FOR US. [XXX] *TR UPDATED 06/24/10 *BF RECEIVED PHOTOS. UPDATED 06/25/10.*JB

Mileage: 5,200

STRONG SMELL OF GAS WHENEVER I FILL UP. UNABLE TO LOCATE ANY LEAKS RIGHT NOW. STRONG GAS ODOR WILL LAST UNTIL I DRIVE FOR 50 MILES OR MORE. *TR

Mileage: 36,000

I JUST NOTICED THE POSTING ABOUT THE FUEL LEAKS IN 2004 CORVETTES. I HAVE BEEN NOTICING A STRONG FUEL SMELL IN MY GARAGE AFTER DRIVING MY CORVETTE. THE SMELL SUBSIDES AFTER A DAY OR TWO, AND NO EVIDENCE OF LEAKS CAN BE SEEN UNDER THE CAR. PERHAPS THERE SHOULD BE A RECALL TO HAVE THESE CHECKED OUT. *TR

Mileage: 24,000

SMELL OF FUEL INSIDE THE HOUSE AFTER PARKING MY CORVETTE IN THE ATTACHED GARAGE ABOUT 3 HOURS AFTER RETURNING HOME. UPON INVESTIGATING THE SOURCE OF THE ODOR, DISCOVERED POOL OF GAS DRIPPING UNDERNEATH CAR ON THE DRIVERS SIDE. CONCERNED GAS COULD IGNITE FROM HOT EXHAUST, SPARK, OR DISCARDED CIGARETTE FROM SOME OTHER MOTORIST. *TR

Mileage: 28,754

PURCHASES 2004 CORVETTE. WHEN I FILLED UP GAS TANK, FUEL ODOR WAS EVIDENT. THE GAS SMELL FILLED MY GARAGE AND WENT INTO THE HOUSE. I TOOK TO CHEVROLET DEALER, WHO SAID THAT A SMOKE TEST SHOWED A FUEL LEAK NEAR WHERE THE TANK IS LOCATED. A MORE DETAILED DIAGNOSIS WOULD COST ABOUT $1000, AND ANY WORK WOULD BE ADDED TO THAT. *TR

Mileage: 25,850

FUEL LEAK BY LEFT SIDE FUEL TANK ALL THE TIME[ STEADY DRIP] I HAVE DONE NOTHING TO REPAIR PROBLEM AT THIS TIME VEHICLE IS UNSAFE TO DRIVE. *TR

Mileage: 18,200

LEAKING FUEL TANK OR FUEL CONNECTOR. UPON FILLING GAS TANK, GASOLINE LEAKED FROM FILL CONNECTOR OR FUEL TANK, CAUSING LARGE SPILL ON THE GROUND, VERY FUMY. *TR

Mileage: 13,500

OUR 2004 CORVETTE WITH 27,630 MILES SUDDENLY BEGAN LEAKING GAS FUMES SO SEVERELY IN OUR GARAGE THAT WE WERE CONCERNED WE COULD HAVE AN EXPLOSION. WE ALSO COULD NOT SLEEP IN OUR BEDROOM AT THE OPPOSITE END OF OUR HOUSE DUE TO THE GAS FUMES. WE HAD NOT HIT ANYTHING OR HAD ANYTHING UNUSUAL HAPPEN TO OUR VEHICLE AND WE HAD A GM DEALER IN CHANDLER, AZ DETERMINE THERE WAS NO DAMAGE TO THE UNDERCARRIAGE OF THE CAR. THE DEALER DETERMINED THAT THE DRIVER'S SIDE GAS TANK HAD CRACKED NEAR THE TOP OF THE TANK. WE CONTACTED GM CUSTOMER SUPPORT AND AFTER WE WAITED A WEEK, WITH THE CAR AT THE DEALER'S LOT, GM DETERMINED THEY WOULD DO NOTHING! THEY REFUSED TO EITHER RECALL THE CORVETTE, ADMIT THERE IS A DEFECT IN THEIR GAS TANKS OR ASSIST FINANCIALLY IN REPLACING THE GAS TANK. WE THEN HAD THE GM DEALER REPLACE THE TANK AT A COST OF $1,991. THIS PRICE IS AFTER THE DEALER REDUCED THE COST BY GIVING US A 10% GOODWILL PRICE REDUCTION. DUE TO THE SERIOUS SAFETY DEFECT IN GM'S GAS TANK AND CROSSOVER SYSTEM, WE BELIEVE GM SHOULD IMMEDIATELY RECALL THE 2004 CORVETTES AS VARIOUS OTHER OWNERS HAVE REPORTED THAT THEIR DRIVER SIDE GAS TANK HAS CRACKED AND LEAKED FUEL AND GAS FUMES. THIS IS A SAFETY RECALL AND DEFINITE EPA ISSUE. THE VEHICLE AND OUR GARAGE CERTAINLY COULD HAVE EXPLODED AND THE VEHICLE WAS UNDRIVEABLE WHILE LEAKING FUMES. IT CERTAINLY COULD NOT HAVE PASSED AN EMISSIONS TEST. IS GM WAITING FOR AN EXPLOSION BEFORE THEY ACT? *TR

Mileage: 27,630

I HAVE A 2004 CORVETTE COUPE AND I AM HAVING A GAS SMELL OR LEAK FROM MY CROSSOVER CONNECTOR ON MY GAS TANK. AFTER READING MANY ARTICLES FROM OTHER CORVETTE OWNERS I KNOW THAT THIS IS A SERIOUS PROBLEM AND SHOULD BE A RECALLED ITEM. THIS IS A SAFETY HAZARD AS THE GAS TANK AND LEAK COMES RIGHT OVER MY DUAL EXHAUST AND COULD CAUSE A FIRE.

Mileage: 77,100

CHECK ENGINE LIGHT ON - STRONG FUEL ODOR INTERIOR AND EXTERIOR - GAS LEAKING UNDER DRIVER SIDE ON GARAGE FLOOR AFTER FILLUP. MILEAGE 17,940. CERTIFIED CORVETTE DEALER MECHANIC REMARKED THAT SEALS WERE DEEMED FLAWED. GM NEEDS TO ISSUE SAFETY AND ENVIRONMENTAL RECALL AND REIMBURSE. HAD TO HAVE FUEL TANK REPLACED - COST TOTALED $2,500.59! PLEASE INVESTIGATE THIS DANGEROUS SAFETY ISSUE AND FORCE GM TO RECALL AND REIMBURSE. *TR

Mileage: 17,940

MY 2004 CORVETTE Z06 LEAKED GASOLINE FROM THE HOSE THAT INTERCONNECTS BOTH FUEL TANKS. THE TANKS AND CONNECTOR WERE REPLACED BY EXTENDED WARRANTY BUT THEY WERE REPLACED WITH ONE OF SIMILAR IDENTICAL DESIGN. AFTER DOING SOME RESEARCH IT SEEMS LIKE THIS WAS NOT A ONE CASE EVEN M ANY 2004 OWNERS REPORT THE SAME ISSUE. CONSIDERING THE RISK OF THE PROBLEM A MORE APPROPRIATE REDESIGN SHOULD BE PERFORMED. *TR

Mileage: 12,000

STRONG SMELL OF FUEL INSIDE THE CAR AND OUTSIDE THE CAR IN THE VICINITY OF THE GAS TANKS. *TR

Mileage: 50,500

STRONG GASOLINE SMELL FROM DRIVERS SIDE PASSENGER COMPARTMENT UPON GAS FILL. *TR

Mileage: 21,000

IN 2007 I WAS FILLING MY CAR UP WITH FUEL. WHEN I GOT HOME I NOTICED A LEAK ON MY GARAGE FLOOR. THIS HAPPENED ONLY WHEN I FILLED OVER HALF A TANK. AFTER FINDING A KNOWLEDGEABLE MECHANIC TO HANDLE THIS JOB, THEY REMOVED THE TRANSAXLE TO EXPOSE THE FUEL TANKS, WE REALIZED THAT IT WAS A LEAK IN THE CRACKED CONNECTOR OF THE LEFT HAND TANK, WHERE IT JOINS WITH THE CROSSOVER PIPE. I HAD TO ORDER A NEW LH TANK AND A CROSSOVER PIPE FROM THE US AND AFTER HUGE EXPENSE AND MONTHS WITHOUT MY CAR, WE FINALLY FIXED THE PROBLEM. NOW IT SEEMS THIS IS A COMMON PROBLEM ARISING IN THE 04 CORVETTES AND NEEDS TO BE ADDRESSED BEFORE A FUEL FIRE FATALITY HAPPENS. *TR

Mileage: 8,400

2004 CHEVROLET CORVETTE COUPE LEAKING DRIVER'S SIDE FUEL TANK. STARTED LEAKING ABOUT JULY 2009 AFTER DRIVING APPROXIMATELY 8300 ORIGINAL MILES BY ORIGINAL OWNER. LEAK BECAME WORSE OVER TIME AND RESULTING IN STRONG GASOLINE SMELL. HAD DEALER INSPECT THE CAR, HE DETERMINE THAT THE FUEL TANK LEAKS AT THE CROSSOVER CONNECTION OF THE LEFT TANK. I WAS CONCERNED ABOUT THE FIRE HAZARD HAVING THE CAR IN THE GARAGE WHERE A GAS FIRED WATERHEATER IS LOCATED. I HAD THE CAR REPAIRED BY THE CHEVY DEALER ON JANUARY 12, 2010, AT A COST OF $2083.-. THE REPAIR CONSISTED OF REPLACING THE LEFT FUEL TANK. I ALSO NOTICED THE CAR'S MILEAGE DROPPED FROM ABOUT 16MPG TO LESS THAN 12MPG IN CITY DRIVING. *TR

Mileage: 8,300

FUEL LEAK IN CROSSOVER PIPE WAS DISCOVERED AFTER STRONG FUMES IN CAR AND GAS LEAKING UNDER CAR. THIS HAS HAPPENED ON MY CAR PLUS ONE OTHER OF THE SAME MODEL YEAR AND PURCHASED AT THE SAME TIME.. *TR

Mileage: 65,000

LEFT SIDE FUEL TANK LEAKING AND DRIPPING FUEL ON GARAGE FLOOR. FUEL APPEARED TO BE LEAKING FROM THE TOP OF THE TANK. IMMEDIATELY TOOK TO CHEVY DEALER SERVICE DEPT. AND THEY LATER INFORMED ME THE GAS TANK WAS CRACKED AND NEEDED TO BE REPLACED. TOTAL COSTS $1768.00. *TR

Mileage: 31,244

IN LATE 2003 AND THE 2004 CHEVY CORVETTE MODELS WENT FROM A RUBBER CROSSOVER TUBE TO A METAL ONE. SOMETHING IN THE NEW SYSTEM CAUSES THE FUEL TANK TO CRACK NEAR THE CONNECTOR OR THE SEALS TO FAIL. THIS ALLOWS FUEL AND HEAVY VAPORS TO LEAK AND THE VAPORS GO RIGHT INTO THE CABIN. NEEDLESS TO SAY THIS IS A HUGE SAFETY ISSUE NOT TO MENTION AN EMISSION PROBLEM. *TR

VERY STRONG GASOLINE SMELL WHEN CAR IS PARKED IN GARAGE. *TR UPDATED 07/26/10.*JB

Mileage: 19,600

FUEL SMELL WHEN FILLING CAR WITH GAS ODOR IS ALSO IN CAR. *TR

Mileage: 53,000

I KEPT GETTING STRONG FUEL ODORS IN MY GARAGE BUT NEVER COULD LOCATE THE LEAK. I WENT TO FILL UP AND GAS RAN DOWN THE PAVEMENT ON THE DRIVER SIDE. I TOOK THE CAR TO THE DEALERSHIP AND THEY INFORMED ME THAT THE FUEL TANK HAD A CRACK IN AT AND IT SPILLED WHEN I FILLED UP DIRECTLY OVER THE EXHAUST PIPE. THE TANK WAS REPLACED WITH A NEW ONE. THE OLD TANK WAS LEFT AT THE DEALERSHIP. *TR

Mileage: 14,200

2004 CHEVROLET COM.EDITION Z06 CORVETTE. PURCHASED IN SEPT 2008 WITH 5500 MILES FROM THE ORIGINAL SELLING DEALERSHIP. NOW WITH APPROX 9800-10,000 MILES A FUEL LEAK HAS DEVELOPED WHEN FUELING THE CAR UP. AT APPROX +1/2-3/4 TANK FUEL SPILLS OUT UNDER THE CAR ON THE DRIVERS SIDE. THIS YEAR SAW AN INSTALLATION OF A NEW STAINLESS FUEL CROSSOVER LINE BETWEEN THE TANKS. THEY HAVE BEEN NOTORIOUS FOR LEAKAGE ALONG WITH THE DRIVER'S SIDE TANK IN THE AREA WHERE THE CROSSOVER LINE COUPLES TO THE TANK. ALONG WITH WHAT I CONSIDER A MAJOR SAFETY RISK DUE TO THE POSSIBILITY OF FIRE, (THE EXHAUST AND FUEL TANK ARE IN VERY CLOSE PROXIMITY) THIS ALSO MUST BE AN EPA/EMISSION VIOLATION FROM ESCAPING FUMES, VAPORS AND FUEL. THIS VEHICLE HAS BEEN PAINSTAKINGLY MAINTAINED AND IS IN AS NEW CONDITION (10,000 MILES) THIS IS A DEFECT FROM GM AND DUE TO THE INHERENT POSSIBILITY OF LOSS OF LIFE AND/OR PROPERTY DAMAGE SHOULD BE RECALLED OR AT LEAST REPAIRED BY AN AUTHORIZED GM DEALERSHIP. THIS VEHICLE DOES HAVE A 80,000 MILE EMISSION WARRANTY UNDER WHICH THIS FALLS. *TR

Mileage: 10,000

ON JUNE 25, 2009 I POSTED THE FOLLOWING THREAD ON THE CORVETTE FORUM WEBSITE: I BEGAN PUMPING FUEL SLOWLY AND WHEN THE FUEL STARTED TO SPILL UNDER THE CAR I STOPPED AND I COULD NOT DETECT THE LEAK POINT. THE FUEL GAUGE READ OF A TANK. AFTER A SHORT TIME PERIOD THE FUEL QUITS LEAKING. I AM GUESSING THAT I HAVE A CRACK IN THE FILL TUBE. COULD SOMETHING ELSE BE GOING ON THAT I AM NOT AWARE OF BESIDES A FILL TUBE CRACK? WOW, OF ALL THE THINGS THAT COULD GO WRONG WITH A CAR, THIS IS A FIRST FOR ME. THE SECOND TANK CONNECTOR JOINT ON MY CAR IS SPLIT ALSO. I WENT TO THE DEALERSHIP TO CHECK IT OUT FOR MYSELF. THEY PRESSURED UP THE TANK WITH NITROGEN/SMOKE AND SMOKE WAS POURING OUT OF THE CONNECTION JOINT. BAD NEWS...........$2400 TO REPAIR WITH NEW PARTS AND 9 HRS. OF LABOR..........THE GREAT NEWS.. THANK GOD FOR MY GMPP, IT'S COVERED. MY ONLY COMPLAINT IS WHY GMPP WOULD NOT COVER TO HAVE THE PARTS OVERNIGHTED FOR $100?? THEY WILL PAY THE EXTRA THREE DAYS OF CAR RENTAL INSTEAD, FOR A TOTAL OF 5 DAYS. JUST DOESN'T SEEM TO MAKE GOOD BUSINESS SENSE, OH THAT'S RIGHT IT'S GM!! FURTHER MORE THE CAR ONLY HAS 34K MILES ON IT, NEVER HAD THIS ISSUE WITH ANY OTHER VEHICLE. *TR

Mileage: 34,000

GASOLINE SMELL/LEAK WHEN YOU FILL THE TANK ON MY 2004 CHEVROLET CORVETTE. THERE SHOULD BE A RECALL AS THIS IS A COMMON PROBLEM. *TR

Mileage: 9,642

2004 CHEVROLET CORVETTE ALL... FAULTY FUEL TANK CROSSOVER CONNECTOR CRACKS AND ALLOWS FUEL TO SPILL PROFUSELY ONTO THE GROUND AND VAPORIZES ON COMPONENTS NEAR THE EXHAUST SYSTEM. LIMITED TO 2004 DUE TO MFG CHANGE IN THAT YEAR. *TR

Mileage: 34,000

2004 CORVETTE FUEL LEAKS ON CROSSOVER TUBES BETWEEN TANKS. FAULTY SEALS, ASSEMBLY. FUEL VAPORS, FUEL LEAKS WHILE FUELING AND AFTER. MAXIMUM TANK CAPACITY WITHOUT VAPORS AND LEAK IS 1/2 TANK. COST TO CORRECT IS UPWARDS OF 2K. A LARGE QUANTITY OF 04 CORVETTES HAVE THIS PROBLEM. STILL NOT REPAIRED AT THIS TIME DUE TO AWAITING IF GM WILL FINALLY ADMIT FAULTY SYSTEM DESIGN. *TR UPDATED 003/30/10 *BF UPDATED 10/05/10

Mileage: 52,000

IF YOU GO THE CORVETTE FORUM ONLINE YOU WILL SEE AN ONGOING DISCUSSION ON 2004 CORVETTES WITH FUEL TANK/CROSSOVER PIPES VENTING FUMES AND OR LEAKING. IT SEEMS LIMITED TO THE 2004 MODEL AND THE PROBLEM IS CRACKING FUEL TANKS OR BAD CROSSOVER PIPE SEALS THAT REQUIRE TANK REPLACEMENT TO REPAIR. THEY ARE CHARGING UPWARDS OF $2,400.00 TO REPAIR THIS! SINCE IT VENTS RAW FUEL AND OR FUMES INTO THE AIR I FEEL THIS SHOULD BE A RECALL FOR SAFETY REASONS BESIDES THE EMISSION VIOLATION! THIS IS A VERY COMMON PROBLEM ON THIS MODEL AND SHOULD BE LOOKED INTO BEFORE SOME ONES CAR EXPLODES! *TR

Mileage: 36,000

TL*THE CONTACT OWNS A 2004 CHEVROLET CORVETTE. AFTER GASOLINE WAS PLACED IN THE VEHICLE AND IT HAD BEEN PARKED FOR A WHILE, THE CONTACT NOTICED THAT ALL OF THE FUEL WAS LEAKING UNDERNEATH THE DRIVER'S SIDE OF THE VEHICLE. THE DEALER STATED THAT THE FUEL LEVEL SENSOR WAS THE CAUSE OF THE FAILURE. THE CONTACT STATED THAT THE ORIGINAL OWNER OF THE VEHICLE HAD THIS COMPONENT PREVIOUSLY REPAIRED AND IT SHOULD NOT BE FAILING AGAIN. THE VEHICLE HAS NOT YET BEEN REPAIRED BECAUSE SHE FEELS THAT THE MANUFACTURER SHOULD HAVE REPAIRED IT CORRECTLY WHILE IT WAS UNDER RECALL. THE CURRENT AND FAILURE MILEAGES WERE 5,800.

Mileage: 5,800

2004 CORVETTE, COUPE. STRONG ODOR OF GAS ON EVERY FILL UP. PARTICULARLY STRONG ODOR ON THE DRIVERS SIDE. NO INDICATIONS OF GAS LEAKING ON THE GROUND, GAS ODOR IS STRONG INSIDE THE VEHICLE ALSO. ODOR DISAPPEARS WHEN THE TANK IS ABOUT 1/2 FULL. *TR

Mileage: 26,700

THERE WAS A HEAVY GAS SMELL AND THE CHECK ENGINE LIGHT CAME ON. TOOK THE VEHICLE TO A CHEVROLET DEALER TO CORRECT. THEY SAID THE GAS TANK HAD A LEAK ON THE TOP OF THE TANK. I THOUGHT THIS STRANGE BUT HAD THEM REPLACE IT. THERE WAS MUCH BACK AND FORTH AND THE DEALER SAID HE WOULD GIVE ME THE TANK AS A CHEVROLET GOOD WILL GESTURE, BUT I WOULD HAVE TO PAY LABOR. *TR

Mileage: 7,400

GASOLINE LINES WERE RESIGNED IN LATE 03 INTO EARLY 04 CHEVY CORVETTES. THE RESULT WAS LEAKING GAS WHICH IS BOTH A SAFETY AND ENVIRONMENTAL HAZARD. GM DEALER REFUSED TO COVER BECAUSE DOM WAS 01/04 AND MILEAGE WAS 11982 WHEN LEAK WAS DISCOVERED. THEREFORE I HAD TO PAY INDEPENDENT AUTO REPAIR SERVICE $1945.45 THIS A MAJOR JOB. EXHAUST, TRANSMISSION, DEFECTIVE LEFT GAS TANK, ETC HAD TO BE DROPPED AND THE MOTOR TILTED TO REPLACE THE GAS LINES AND LEFT TANK. THIS A MAJOR PROBLEM AND GM FACTORY REP SAYS HE IS ONLY WILLING TO COVER $700. HELP. I HAVE ALL DOCUMENTATION INC PICS, LETTERS AND PARTS. *TR

Mileage: 11,982

CHECK ENGINE LIGHT WARNING. RIGHT SIDE FUEL TANK LEAKING. *TR

Mileage: 22,747

NOTICED A GASOLINE SMELL GETTING OUT OF CAR. PUDDLE OF GAS ON GROUND UNDER FUEL TANK. DEALER CHANGED OUT FUEL TANK. SERVICE WRITER SAID THE CROSS OVER PIPE HAD A DEFORMED FITTING. *AK .

Mileage: 19,772

I SMELLED GAS IN MY GARAGE FOR APPROXIMATELY 1 WEEK BUT FOUND NO LEAKS. WHILE FILLING UP AT GAS STATION I NOTICE A LARGE PUDDLE FORMING UNDER CAR AND SAW GAS LEAKING FROM TANK. DEALER SAID GAS LEAK WAS FOUND IN GAS TANK, CROSSOVER FUEL LINE AND TWO OTHER FUEL LINES. VERY DANGEROUS SITUATION. DEALER SAID MANUFACTURER DEFECT IN PARTS. TOOK 10 DAYS TO REPAIR AS THE FIRST TIME TANK WAS REPLACED THERE WAS NO FUEL PRESSURE AND HAD TO BE REDONE. *NM

Mileage: 23,000

SMELLED GAS FOR ABOUT A WEEK AND THEN NOTICED THAT THE CAR WHEN STARTED WAS LEAKING GAS. I TOOK IT TO MY LOCAL DEALER AND HE SAID AFTER INSPECTION THE GAS TANK WILL HAVE TO BE REPLACED. I HAVE BEEN WAITING A WEEK FOR THE REPLACEMENT BUT THE DEALER IS SAYING IT WILL BE ANOTHER WEEK MINIMUM. THEY CANNOT FIND THE TANK. *NM

Mileage: 22,300

GAS TANK LEAK .. BRAND NEW CAR 2004 CORVETTE... GAS WAS LEAKING FROM THE CROSSOVER PIPE ( WHAT DEALER SAID ) NEEDED TO REPLACE THIS AND THE LEFT SIDE GAS TANK. TOOK 25 DAYS TO FIX NO PARTS. BEEN TOLD BY SEVERAL PEOPLE THAT THIS IS FAIRLY COMMON. THIS LEAKED ABOUT A GALLON OR MORE ON MY GARAGE FLOOR COULD HAVE BEEN A VERY DANGEROUS SITUATION AS I HAVE A GAS HOT WATER HEATER AND THERE IS A PILOT LIGHT. FUMES WERE CONSIDERABLE WHEN DISCOVERED. ALSO LEAKED GAS WHILE DRIVING WITH DRIPPING AND NOTICEABLE GAS. *AK

Mileage: 100

WHILE THE VEHICLE WAS PARKED, THE CONSUMER NOTICED THAT FLUID WAS LEAKING FROM UNDERNEATH THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION. THE MECHANIC INFORMED THE DRIVER THAT THE GAS TANK NEEDED TO BE REPLACED. PLEASE PROVIDE FURTHER DETAILS. *JB

SMELL GAS ODOR OUTSIDE THE CAR, MOSTLY ON THE DRIVER SIDE. GAS LEAKS FOUND BY THE DEALERSHIP ON THE DRIVERSIDE FUEL TANK, SEAL ON THE FUEL PUMP, AND THE INTERCONNCTING HOSES FOR BOTH TANK. ALL PARTS REPLACED.*AK

Mileage: 7,000

I HAVE A BRAND NEW 2004 CORVETTE 1 1/2 MONTHS OLD WITH ONLY 1341 MILES ON IT. WHILE DRIVING HOME IN RUSH HOUR DALLAS TRAFFIC ON A VERY BUSY FAST MOVING ROAD, MY ENGINE DIED IN THE MIDDLE OF THE ROAD. I COULD NOT RESTART THE CAR & WAS IN A VERY SERIOUS SITUATION RISKING THE POSSIBILITY OF BEING REAR ENDED. LUCKILY A POLICEMAN CAME BY AND PARKED BEHIND ME TO SHIELD ME FROM THE TRAFFIC. IF I HAD BEEN ON THE FREEWAY, I COULD HAVE BEEN KILLED. THE GM DEALER WHERE I PURCHASED THE CAR (RAY HUFFINES CHEVROLET OF PLANO) IS ACTING LIKE IT IS NO BIG DEAL. THEY SAID IT IS THE FUEL PUMP & THEY WILL REPLACE IT WHEN THEY CAN GET A FUEL PUMP AND IF IT HAPPENS AGAIN, TO BRING IT BACK. IF IT HAPPENS AGAIN & I WOULD BE ON THE FREEWAY, I MORE THAN LIKELY WOULD NOT BE ALIVE TO TAKE THE CAR BACK IN. I DRIVE 50+ MILES A DAY TO & FROM WORK MOSTLY FREEWAY DRIVING. I FEEL THE DEALERSHIP IS TRYING TO PUT MY LIFE IN JEOPARDY. I WANT MY MONEY BACK AND OUT OF THIS CAR. IN RESEARCHING, I HAVE FOUND THAT 127,000 2004 CORVETTES HAVE BEEN RECALLED FOR STEERING PROBLEMS. I WAS NEVER ADVISED OF THIS WHEN I PURCHASED THIS CAR OR OF ANY FUEL PUMP ISSUES. I HAVE PURCHASED A BRAND NEW CAR EVERY 3 YEARS FOR THE LAST 20 YEARS & I HAVE NEVER HAD A PROBLEM LIKE THIS, ESPECIALLY WITH A BRAND NEW $50,000 CAR AND I HAVE OWNED 280ZX, 300ZX, RX7, SUPRA, AND LEXUS. I NEED HELP FROM GM OR SOMEONE TO RESOLVE THIS. *JB

Mileage: 1,341