Tank Assembly Problems of Chevrolet Corvette - part 2

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?.

See all problems of the 2004 Chevrolet Corvette 🔎.

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.

Fuel tank leaks when fueling car. This seems to be a common issue with the Chevrolet Corvette in the years 2000-2004. On all public forums this defect is reported by many Corvette owners. Why isn't the epa or the NHTSA investigating all of the years instead of just the 2004 models? the recall should be expanded. What is the delay? should someone die in a fire first? or should we band together and file a class action suit against all parties, including the NHTSA.

See all problems of the 2002 Chevrolet Corvette 🔎.

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

Fuel leaking from the gas tank along with strong odor of gas. I purchased this vehicle in Feb 2010 I do see a recall for other Corvettes same year, but different VIN#'s. I am concerned there are more vehicles with the same problem that the gm has not looked at . This car was made in the same plant as the others and my car has other recalls that have been taken care that were from that plant bowling green plant code 5. I am certain that those VIN #'s are not the only vehicles with this problem.

See all problems of the 1997 Chevrolet Corvette 🔎.

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.

1. Each time the fuel tank is filled up there is a strong fuel odor smell. 2. Recently there is fuel leakage on my garage floor directly in front of the right rear tire & fuel on the side and bottom of the fuel tank. 3. Gm said car was out of warranty for this issue.

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.

Started with gasoline smell coming from 03 Corvette. Took to dealer and found out that the problem was one of the 2 gas tanks. Unable to know for sure without dropping the whole drive train. This was done and the plastic gas tank had developed a leak. Was informed that this was a flaw with some production Corvettes. A very expensive repair but one that must be done. Cannot have gas vapors escaping into the air or confined in a garage. I have already had 1 house fire, don't need another one. If gm knew about this problem, they should have fixed it. Buyers should not be put in harms way.

See all problems of the 2003 Chevrolet Corvette 🔎.

I have a 2002 Corvette convertible. Each time the fuel tank is filled there is a strong fuel odor smell in the passenger compartment of the car. Even with the top down the smell causes headaches and nausea! all it will require is a single spark to cause death! it is time to force a recall on all 1997 to 2004 c5 Corvettes!.

Fuel tank leak due to a split in non metal tank.

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

Leaky gas tank or cross over. When tank is filled gas leaks and fumes can be smelled for days.

See all problems of the 2001 Chevrolet Corvette 🔎.

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.

The fuel tank leaks when filled to the normal cutoff point when filling. There was no event leading to the failure, it occurs when the fuel tank is filled. The fuel tank needs to be replaced to correct the defective fuel tanks. Gm/chevy does not stand behind the defective tanks and the costs are born by the owner. Gm did not respond to the issue while it was under either the vehicle's extended gmpp warranty nor the emissions warranty, both now just expired.

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.

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.

09 Corvette will only take half-tank of gas,auto-shutoff. To fill tank have to turn nozzle upside down to fill. This method causes fuel over flow and spillage on the ground. Dealer says it is gas pumps here in California that are at fault and not the Corvette. 28 million cars that the pumps work on. This leads me to believe that there will be a fire involved accident as well as pollution escaping from the fill nozzle. . There are 14 other Corvettes here with the same problem. Gm says it is not their problem. Help b4 one of us gets burned to death. It is also defeating the fume recovery system and releasing most into the atmosphere.

See all problems of the 2009 Chevrolet Corvette 🔎.

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.

1) started the vehicle and waited to warm up 2) smelled gas after I started to back up then stopped to see gas on the ground that was originating from under the car at the drivers side gas tank 3) I'm presently trying to have the car towed to a certified gm dealer for analysis and repair.

See all problems of the 1998 Chevrolet Corvette 🔎.

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.

2001 Corvette convertible, with less than 66k miles -- defect/crack in gasoline tank -- resulting in strong smell of fuel and visible leaking from under rear of vehicle -- in front of left rear wheel. Vehicle was taken in for problem on August 21 2006 for repair. Customer was told by both dealership and gm that no 2001 gasoline tank available for immediate repair. Gm and dealership informed customer that 2001 gasoline tank manufacturers were switched -- but no gas tanks have passed inspection, as yet, to allow for customer repair. It has now been 4. 5 months that my 2001 Corvette is still sitting at the dealership -- awaiting a safe gasoline tank to be installed.

1998 Corvette convertible. Two independent situation where gas tanks leaks although car is a secondary car and rarely driven. Gas tank leaked in 2003 prompting service, repair and replacement of parts. Gas tank leaks again which warrants another service, repair and replacement of parts.

Fuel leakage and fuel smells coming from fuel tanks, after fueling.

See all problems of the 2000 Chevrolet Corvette 🔎.

Consumer's vehicle having the same problems a mentioned in recall 97v105000 concerning sending unit. Dealership will not repair free of charge because the VIN was not included. There was gas leaking from the top of the tank. There was no evidence of hose failure.

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.