Tank Assembly problems of the 2004 Chevrolet Corvette - part 2

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 â¾ 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.

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.

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. Updated 003/30/10 updated 10/05/10.

Left side fuel tank leaking gas.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.