Tank Assembly Problems of Chevrolet Suburban - part 1

I have a 2004 chev Suburban with 93409 mile, has been well taken care of. A few months ago I notice it was having a hard time starting. Last wk we ran out of gas at 1. 4 tank and this weekend while the family was on a trip pulling a trailer we ran out of gas at 1/2 tank, if you go by the gas gage. We could have been baddly hurt if we were on a hill, or something when we all of a sudden have no powersteering, brakes, etc.

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We have a 2007 chevy Suburban that has had 2 fuel level sensors replaced under warranty. We are now out of warranty with 48,000 miles on the vehicle and the fuel gauge is again displaying inaccurate fuel levels. We have twice ran out of fuel when the guage showed a quarter tank.

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Fuel gauge malfunctioned on our 2003 chevy Suburban. It indicated more gasoline was in the car than was actually in the tank.

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2003 chevy Suburban 1/2 ton four wheel drive inaccurate fuel level reading on gauge. Ran out of fuel multiple times. At first fuel tank was empty when gauge read 1/8 tank, now empty when gauge reads 1/4 tank. Have not replaced any parts yet as cost would be too much at this time. Just being aware of how much fuel we have used. No injuries or crashes, but this could lead to something serious on the road or expressway if the engine were to shut down because of lack of fuel.

The contact owns a 2007 Chevrolet Suburban. The contact stated that fuel could be smelled from the interior cabin of the vehicle. The contact made repairs to the fuel system but none of the repairs remedied the odor. The contact was able to determine that the fuel tank was leaking and replaced the fitted. The contact stated that since the repair, the fuel odor could only be smelled after refueling the vehicle. The vehicle was not taken to the dealer. The failure mileage was 75,000.

Fuel tank strap rusted and broke causing fuel tank to drop.

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The contact owns a 2001 Chevrolet Suburban 2500. For several days, he smelled fuel and after he added fuel to tank he was receiving and inaccurate fuel level reading. The dealer stated that there were no recalls related to the failure. The manufacturer stated that there were not enough complaints to issue a recall for his year, make and model vehicle. The vehicle was not repaired. The current and the failure mileages were 88,000.

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The contact owns a 2001 Chevrolet Suburban 2500. The contact noticed excessive gasoline leaking from the fuel tank. The leakage occurred continuously and without warning. The vehicle has not been repaired. The VIN was excluded from the recall due to the mileage on the vehicle; however, the failures were identical. The contact was concerned of the safety risk involved. The NHTSA campaign id number and mileages were unknown.

Gas leaking from top of gas tank on Suburban. It has happened four times since June of 2007. Never know when it is going to happen, doesn't happen all of the time, about every 4 months. It isn't a little but a lot causing a puddle and a horrible gas smell for a couple of days in my vehicle. When this happens everyone around the station is astonished at how much it leaks and that I get in the vehicle and drive off. The service department claims to replace a valve when this happens, but then why does it happen again and again. Last weekend this happened to my family (3 kids under 4 are in the vehicle when this happens) while on vacation. Needless to say I was very scared and on the edge of my seat making sure we were not around anything hot or anybody smoking. As one cigarette would have put our vehicle into shooting flames. We were also all exposed to the fumes all weekend long.

I have a 2001 chevy Suburban k2500, it takes me 45 minutes to fill up the gas tank, I believe the air does not escape from the gas tank and it causes it to overflow when filling and may cause fire if unattended since when you press the gas pump to pump faster it overflows and leaks on the exhaust pipe and could cause fire, also gasoline might do harm to environment while overflowing, so, please help, its winter here where we live and 45 minutes at the gas pump is really something, thank you-valentin.

Chevy Suburban 2003 lt 1500 flex fuel v8. Developed fuel tank leak. Remedy is to replace fuel tank. Gasoline dripping down back side of fuel tank. Potential fire/safety hazard to driver and occupants. Vehicle mileage 120k. Age less than 48 months. No collisions except minor to rear bumper. Cost of repair over $1,000. 00.

I have a 2002 Suburban that had a recall for the gas tank leaking when it is filled past 3/4 full. The recall work was done in December 2005. Then in March I smelt gas again I noticed a large puddle was under my vehicle as I pulled out of the garage. I carried it back in and they charged me $890. 00 and stated since the recall work was done in December this would not be covered. I have the parts they replaced.

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Recall repair done on chevy Suburban 2001 which involved taking down the fuel tank (new wiring harness installed). Has serious concern now, that the car is now less safer due the fuel tank mounting and dismounting. In fact my fuel gauge started not working after this and now they have take down the fuel tank again. Is there any evidence that this type of service work may actually cause further safety issues which may involve a vehicle fire ? is this really the proper way to correct a safety issue which has already created a recall ?.

The contact noticed a very strong smell in garage that would almost burn the eyes, and leave a stain on the floor. He contacted the dealership, but since the vehicle was out of warranty they would not offer any assistance. The vehicle was taken to an independent mechanic, who determined that the main plastic fuel tank cracked. There is a hose that goes between the two tanks it was not cracked at the hose, but it was cracked at the top of the plastic tank. The main tank was replaced at contact's expense. The vehicle was never in an accident, and never was used as an off road vehicle. Also, the manufacturer was contacted , and they provided the contact with a case number and explained to him there was nothing they could do about it. This was always noticed after the vehicle was filled up. Updated 1/11/2006 - the consumer filed a complaint with the manufacturer.

: the contact stated while driving at various speeds, the check engine light illuminated. Afterwards, the odor of gasoline was present. The vehicle was seen by a dealer for inspection. The dealer determined the fuel tank assembly was cracked and needed to be replaced. The vehicle was taken to an independent repair shop for replacement of the fuel tank assembly which corrected the problem.

There is recall # 05v155000 for the fuel module reservoir assembly where the wire breaks the seal in the gas tank. Contacted the dealer. They took the gas tank off and that the fuel module was bad. The wire got warm and caused a hole in the connector, and fuel vapors leaked out, and engine light appeared on August 25, 2005 . That was why I the consumer took the vehicle to dealer. When the gas got low the gas gauge would go all the way to and back to the actual amount of gas that was in it.

On both my 2003 chevy Suburban, and 2002 chevy k2500 truck, the gas gauge reads erroneously. Tends to get hung up at 1/4 tank, then later goes to empty. . . At which time I've run out of gas! chevy replaced the burb fuel sensor twice, and the truck once. . . Under warranty. Past warranty they will not help. Safety issue: I ran out of gas in downtown atlanta, interstate traffic during rush hour, had to weave my dead truck through 70 mph traffic to the left shoulder. Very dangerous move. . . Luckily was not rear-ended! have friends w/ same truck. . . Same problem.

Gas tank leak as described in previous reported claims.

In may 2004 I noticed a gasoline smell in my garage. Upon investigating it was coming from inside the gas tank guard on my 1999 Chevrolet Suburban. After removing the guard a small pinhole leak was detected in the tank. The tank had rusted through due to an inability of water, salt, and debris to be cleared from the guard because it contains no drain holes. I repaired the tank with an over the counter repair kit due to the need of the vehicle. I contacted Chevrolet but was told that since I fixed the tank myself there was nothing they could do for me. On 11/07/04 I again noticed gas fumes in the garage. Upon looking I discovered two new holes rusted through the tank. At this point I don't know what to do because I fear the tank is rusted too thin to rely on for safety reasons. I believe a general engineering oversight would allow a plastic bowl shaped guard to be strapped below a metal tank without at least some drain holes to allow water to escape. I'm writing because we keep the Suburban in excellent repair and I'm possitive there are other such designed tanks with the same problem.

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Fuel leak with full tank on level ground. Appears similar to defect summary ea04026. Vehicle had had fuel sensor replaced 06/2002 at 36000 miles for sporadic fuel gage / temp gage failures. Expect this is caused by the melted electrical terminals at pump module. Possibly related to sensor replacement. Does not leak on level after driving 10 miles after fillup, but will leak if pointed down hill - very noticeable fuel leak. Certainly a fire hazard. Have talked with Chevrolet 1-800-222-1020. They acknowledge the "engineering analysis" but will not authorize footing the bill for repairs.

2000 Chevrolet Suburban, gas tank cracked around fuel pump. Needed to be replaced. The fuel pump also makes a loud whinning noise.

2002 Chevrolet Suburban VIN# 3gngk26g11g219028 dealer reported coolant line failure caused by friction of metal coolant line rubbing against fuel tank. Dealer refused to repair and remove/repair cause of line coming into contact with fuel tank.

Consumer states the fuel pump module (connector) was leaking fuel due to a fuel pump wire that had melted inside the fuel tank. Gm replaced the 10-amp fuse with a 20-amp fuse. This caused a fuel leak. Consumer wondered why the fuse didn't blow to prevent leakage. Gm did offer a 45/55 split but the consumer wouldn't be informed of the findings after an investigation was completed.

Consumer states the can't get no gas at all due to fuel tank is not ventilate. Dealer notified many times. Please provide further information.

When filling the gas tank, the pump cuts off at 3/4 full. When I try to fill it all the way, it over flows onto the ground after the pump cuts off again. The dealer (team Chevrolet) says there is nothing wrong with the tank. They say it is the gas station I am using or I should just hold the gas nozzle myself until it is full.

After fueling vehicle fuel tank leaked. Had vehicle serviced,there was a leak in fuel tank.

After fueling vehicle the night before there was a puddle of fuel underneath vehicle, the next day the vehicle was taken to the dealer who sad it was caused by a defect in the fuel tank.

Consumer states that fuel tank assembly has a malfunction. When consumer is putting fuel into his vehicle the nozzle at the gas station keep cutting off, which indicates that the tank is full, but the tank isn't. So you have to keep fueling and esitmating when the tank is full. Nlm.

Consumer smelled gas in and outside of vehicle with bubbling sounds from fuel tank. When consumer opened fuel tank a 12 foot stream of fuel sprayed out of tank. Dealer has been contacted, and could not duplicate problem. Please provide further information.

Consumer can hear truck percolating. Also, can smell gas coming from vehicle, and it goes all through house.

I am concerned about the fact that in this size of vehicle that the fuel tank ruptured and that the doors crimpled so bad that the passengers were unable to get out of the vehicle in a timely manner. Please contact me concerning this. Thank you.

No summary listed for abov evehicle.

Constant fuel leak and smell in for repair 4 times nothing left to fix still leaks.

Gas tank leak.

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When filling vehicle with fuel, fuel blew back out on consumer's hand. Dealer has been notified. Dealer was unable to duplicate problem. Please provide further information.