Other Fuel System Tank Mounting Problems of Chevrolet Tahoe

Fuel line above gas tank wore a hole spraying a significant amount of gas around rear exhaust and brake rotors. The hole in the fuel line was due to not being properly protected from normal wear and vibration where it made contact with the gas tank assembly and vehicle frame. The hole occurred after very normal use of the vehicle at around 81,000 miles. The car has been used 99% of time on city streets and highways.

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Fire hazard explosion hazard environmental hazard. While in motion pressurized fuel lines at the furl pump can unexpectedly fail due to corrosion resulting in fuel being pumped out of the vehicle onto the under surfaces of the vehicle and the roadway. As much as 25 gallons of fuel can be expelled from the vehicle while in motion with no warning to the driver other that a rapidly diminishing of amount of fuel remaining as shown by the fuel gage. The vehicle was being driven on an interstate highway when the fault occurred but it was not noticed until the vehicle exited the highway at which time a strong odor of gasoline was noticed. When the engine was shut off and the vehicle exited a pool of gasoline was observed under the rear of the vehicle. The vehicle was towed to a repair facility. During the repair it was noted that the fuel pomp is located at the top of the tank and could be observed without removing the tank from the vehicle. Upon removal it was found the pump mounting lacation was in a well molded into the plastic fuel tank. The well was full of sand and dust which was cleaned out revealing a mass of rust on the steel fuel pump support and locking ring as well as the steel pressure and return lines. The leak was determined to be in the pressure line line inside the plastic fuel line quick connect both steel fuel lines disintegrated while attempting to disconnect the plastic lines from the tank. Repairs included the replacement of the fuel pump, both plastic fuel lines and quick connects. These components are identical. To those originally installed and will be subject to the same corrosion as the originals due the to the poor design of the pump placemen ton the tank and the failure to shield the components from being covered with sand an dust, particularly in areas where salt is used on the roads in winter.

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The top of the poly fuel tank has a recess for the electric fuel pump assembly which is gasket mounted within the tank. The two inch fuel line connectors atop the pump are metal. Due to the design of the poly fuel tank, water can collect within the recess and cause the metal lines to rust-out at the connection bends for the poly fuel lines to engine. The smell of gas starts out as being subtle, however become stronger as the rust pin holes get larger. The gasoline leakage occurs while the vehicle is in operation. This is can be a major safety hazzard if someone throws a smoking butt on the highway. There should be a recall to repair this design.

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Smelled gas coming from the rear passenger side of the car (on exterior) and was informed that the metal ring molded into the plastic tank where the sending unit mounts to the tank had rusted out and gas was accumulating in the "bowl" that the connection is in. Rusting is a result of water accumulating in the "bowl" where the unit mounts and not being able to drain out. Did some online research and found that a number of Tahoe owners have had the same issue. Was also informed that Chevrolet determined this was an issue and changed the design of the tank in future models to remove the metal ring that the sending unit mounted to. Cost to repair at Chevrolet and independant garage $2,000 or more.

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The fuel gauge will read the correct amount of fuel until it is about 3/4 to 1/2 a tank then start bouncing up and down then it will go all the way to empty and the fuel light comes on even though it has plenty of fuel. I have been driving down the road with my kids in the car and ran out of gas even though it regisiters fuel above the red mark and no low fuel light on. I know have ran out of gas several times and fear it might put myself or my family in a bad situation. I don't understand why this is happening and wish someone (gm) would help their loyal customer base. As it appears with more research I do this is a serious ongoing problem that spans different models and years.

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