Tank Assembly problems of the 2004 Chevrolet Corvette - part 1

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.

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.

Strong gas fume's when tank is half full.

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).

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.

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.

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.

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 pictures received. Updated 09/20/10.

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.

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.

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!.

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.

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.

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.

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.

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 received pictures. Updated 09/27/jb updated 12/01/10. Gm provided 50% of the initial cost and later the other 50%. Updated 12/07/10.

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.

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.

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.

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] updated 06/24/10 received photos. Updated 06/25/10.

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.

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.

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.

The gas tank is leaking on my 2004 Corvette.

Drivers side gas tank has a leak nita's has open investigation on this complaint.

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?.

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.

Strong smell of fuel inside the car and outside the car in the vicinity of the gas tanks.

Fuel leak on 2004 Chevrolet Corvette. Strong gasoline odor inside the vehicle. Tank leakage if filled for $20 or more of gasoline.

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.

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.

Gasoline smell/leak when you fill the tank on my 2004 Chevrolet Corvette. There should be a recall as this is a common problem.

Smell of gasoline when stopped and after car is parked overnight. Updated 08/04/10 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.

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.

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.