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"

- New Braunfels, TX, USA

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. www-ODI.NHTSA.dot.gov/cars/problems/defect/results.cfm?action_number=PE10015&searchtype=quicksearch&summary=true

- Hilo, HI, USA

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.

- Pompton Plains, NJ, USA

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.

- Orlando, FL, USA

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. Updated 10/17/2017

- Freehold, NJ, USA

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.

- Bothell, WA, USA

Engine light came on, took to mechanic, fuel vapor/fuel leak identified, smoke test performed, source appears to be tank/tank straps.

- The Woodlands, TX, USA

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

- Kernersville, NC, USA

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 updated 4/7/2015

- Schenectady, NY, USA

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.

- Brookville , OH, USA

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 to fix. Corvette forum states this is a common problem. This is a safety issue I woulld think.

- Rockford, IL, USA