Tank Filler Pipe And Cap Problems of Chevrolet Trailblazer - part 1

Tl the contact owns a 2004 Chevrolet Trailblazer. The contact stated the he noticed a fuel odor emitting from underneath the driver's side of the vehicle. The contact also stated that the fuel mileage had also decreased when driving the vehicle. The contact took the vehicle to have an evap smoke test performed on his vehicle. The result of the test discovered that a crack had formed on the fuel neck that connects to the fuel tank, which was the cause of the failure. The contact then spoke with j. B. A. Chevrolet (7327 ritchie hwy, glen burnie, MD 21061) where he was informed that there were no recalls on the vehicle for the failure. The manufacturer was notified of the failure. The vehicle was not repaired. The failure mileage was approximately 126,432.

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My car has been swallowing gas. It uses 1 gallon per 5 or 6 miles, it doesn’t accelerate, and it keeps turning off when I slow down, and I have to re-start it. It has become very unsafe for me and all the drivers around me. I took to the dealer. They said they checked it, and they replaced only one little gas cap. They said that it will take care of the problem. It didn't. I still have the same problem of high fuel burning. I took it back to the dealer. They checked again. They said the fuel tank needs to be replaced and they want to charge me $1027 to replace the fuel tank. Several mechanics told me that there was recall on fuel system on my type of vehicles. I shared the recall information with the dealer, but they said that there is not recall. I have checked recalls on line, and have checked more. Others drivers have had similar problem. . Read more...

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The contact owns a 2003 Chevrolet Trailblazer. The contact stated that there was an overpowering gasoline odor in the vehicle. The manufacturer was contacted and advised that the failure was caused by the fuel tank. The vehicle was inspected by the dealer who advised that the failure was with the filler cap and fuel was leaking from the vehicle. The vehicle was not repaired. The contact believed that the manufacturer should be liable for the repairs because of the safety hazard involved. The failure mileage was unknown and the current mileage was 129,400. The VIN was not available.

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The fuel gauge level indicator just went from "full" to "empty", it just went that fast. Minutes before it had just been filled at the gas station. When starting, the gauge rises then falls to empty. On occasions the warning message, "please tighten gas cap" comes on. Now months later, same problem; after contacting "gm" hotline, they still have not shown any concern. I keep track of miles driven since last fill-up and gas used, so I know when it is time to fill-up. I have read many same complaints, and I wonder why "gm" has not issued a recall. It is now 08/21/2012 and problem is still ongoing. Can you please help. Please. "gm" has on numerous occasions suggested that the wire harness on top of the gas tank needs to be replaced, to do so, requires a five (5) hour visit and they expect the customer to pay half the cost. Please help.

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I noticed a strong fuel odor coming from the vehicle. I researched the manufacturers TSB's and discovered there were two voluntary recall campaigns that had fuel odor symptoms. I inspected the components and found I had both issues, rusted feed and return lines on the fuel pump and a fractured filler neck on the tank. Gm extended the warranty to 10 years and 150000 miles on one issue and 10 years and 120000 miles on the other. I currently have 158000 miles on my vehicle. My issue is with the voluntary recall notice I received. They clearly state that if there is no fuel odor present then do nothing at this time. If I had gone in for inspection at the time the notices were sent out, I would have been under the mileage cap and it would have been fixed under warranty. This is a major safety hazard and should have been a full blown safety recall. A voluntary recall is just a way to skirt the issue and save a buck. How many people are there like me who will not find a problem until it is too late. And it is too late by the time you can smell a fuel odor, that means there is raw fuel escaping from your tank. Now I have had to fix this problem at my substantial expense.

I have been smelling a gasoline odor on the side of my SUV where the fuel door/fuel tank is located. Research on the internet yielded many Trailblazer owners reporting fuel tank/sending unit/pump corrosion resulting in a fuel leak. A family member of mine just had this exact problem repaired on a 2003 Chevrolet Trailblazer. I believe this same issue is starting with my 2002 Trailblazer. I replaced the gas cap to eliminate the possibility of the gas odor coming from the tank fill area, but the odor persisted. The odor resembles an actual gasoline spill and/or leak and not just gasoline vapor odor, filling the tank. Like I stated before, internet research yields many Trailblazer owners reporting this issue and having to pay for costly repairs. Any issue regarding the fuel system/gasoline, in my opinion, should be an immediate safety concern. I have not received any information from gm in regards to a recall bulletin. I am going to conduct more investigation, but in the meantime the smell of a gasoline leak is unmistakable. I hope this information is helpful and I hope that a recourse regarding this issue and its repairs can be formulated. In the meantime I feel that a major safety issue is present and needs fast and efficient attention. Thank you. The consumer stated the fuel pump was severely corroded on the top including two fuel lines that exit the top of the fuel pump. There was a fuel leak resulting from corrosion. The consumer paid for the repairs at his expense. Updated 12/16/10.

Two years ago check engine light came on. Code was gas cap. Replaced cap twice, no improvement. Mechanic then found small leak in neck of fuel tank. Rapid leak, worked fine for two years. Now, on December 7, 2010, check engine light on again. Found that fuel tank filler neck is broken and leaking again. Required a new fuel tank installed at cost of $750 +.

I purchased a 2005 chevy Trailblazer in March 2005, since than the following items has been replaced, just to name a few: fuel tank level sensor (33,104 miles), ho@ sensor shorted (20,205 miles), bearing in idler pulley (25,233 miles), idler pulley bearing failure (47,500 miles), internal clutch circuit (33,896 miles), fuel cap replaced three times, replaced water pump (63,911 miles), air pump relay (77,000 miles). The light unit has been replaced, I was driving and the lights on the radio, doors and other items went out. The vehicle currently has 80,000 miles and I have to replace the fuel tank level sensor again. I have been attempting to get GMC to recall the vehicles, because of the danger involved with the sensor unit sending the wrong signal, meaning the tank could be within a half of a gallon from being empty, but the fuel gauge is reading full. It appears that gm is waiting for multiple deaths to occur before they consider this as being an item that could cause the death of several motorists.

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2004 Chevrolet Trailblazer lt leaking gas & fumes where filler neck joins tank. Have learned online that there are many people having the same problem. Dealer and gm will do nothing to help me pay for the repairs. I paid $1350. 00 to have a new gas tank installed. This must be a defect. I had my vehicle checked several times for the service engine soon light in the past. One occasion was the fuel cap and on another they could find no code. This should be covered. They know they have a problem. My extended warranty ran out 26 days before this happened. Thank you.

I am the owner of a 2003 Chevrolet Trailblazer ext, I purchased the vehicle new from gm. In the last year my ses light has been coming on, I took my vehicle to an auto parts store and they analyzed my vehicle to read the code causing the ses light to come on. I had a leak in my fuel tank emissions system. They recommended I replace my fuel cap to fix the problem. Over the past year and after replacing the fuel cap, the problem would go away for a month or so and they reoccur. I took my vehicle in for a system check of the fuel system. My mechanic performed a smoke test on the fuel system, they told me they found a fracture on a weld with the fuel tank, furthermore they said there was problems with the Chevrolet Trailblazers with faulty welds on the fuel tank. I searched the internet and found auto forum board stating gm has known about this problem for a while. Talking with a CO-worker about my problem, he stated he owned a 2003 Trailblazer and recalled receiving a notice from gm about this problem, he gave me a copy of his notice where the notice talks about fracture of a weld on the fuel tank and Chevrolet providing owners with an extension of repairs for 10 years of ownership or 150,000 miles. I never received a notice from Chevrolet about this program. I called the Chevrolet customer assistance center, where I told them what happened with my vehicle; I also told them I had 167,000 mile on my vehicle. They told me they first needed to verify the crack by a gm dealership mechanic. They also told me I had to pay for the fuel system to be check and there might be some consideration for them to pay for the repair if it was indeed a crack in the fuel system. The crack was confirmed by the Chevrolet dealer, but they told me since my vehicle had over 150,000 miles they would not pay for the repair of my vehicle. The fuel tank is a static system, it should not wear out, I feel gm designed a faulty product and should repair this crack at their cost. Please help me.

My wife's 2004 Trailblazer ext service engine soon light came on in late September 2009. She had been complaining of a gasoline smell after filling the vehicle. I had the obdii code read and it was code 0440 evaporative fuel system - small leak. I was told to replace the gas cap, and it did not remedy the problem. I then found out that the 2002-2004 Trailblazer ext had a known problem with the gas tank filler necks developing cracks and causing the ses light to come on and gas to leak when the tank is filled or near full. I contacted Chevrolet, who stated that out Trailblazer is not in the VIN range of Trailblazer ext's that were covered by a special notice that allowed the tanks to be replaced under a special extended warranty. The replacement cost is $900+. This is a known problem with 2004 Trailblazer ext, outside of the narrow VIN range that Chevrolet will admit to. All 2004 ext's should be included in the extended warranty. Our vehicle just turned 60,000 miles.

I drive a 2006 chevy Trailblazer. After refueling the truck, I noticed the gas cap did not lock properly and the fuel gauge started to jump from empty to full. The check engine light also came on. I immediately replaced the fuel cap but the fuel gauge continued to read inaccurately over the next several weeks. Shortly thereafter, the gauge always reads empty even with a full tank of gas. A chevy mechanic told me the problem was a faulty fuel gauge sending unit in the gas tank. He said the repairs would cost ~$1,000. I cannot afford the repairs and it is a safety hazard to be continuously checking the mileage odometer to assure I don't not run out of gas. My boss has a GMC envoy with the exact same problem. I quick search on the internet reveals several hundred if not thousands of complaints about the same issue. I have almost run out of gas while driving. This faulty gas gauge is a serious safety problem that gm should take ownership for and not require car owners to repair.

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1. Not sure what caused the original failure, but I would say it started after I filled my car with gas 2. It was every time I filled with gas for the first few months, now it is constant and every time my car is in motion. 3. Nothing has been done to correct the problem as the car is out of warranty and cost is well over $800, also they are unsure of the exact problem. Details: my fuel light on my car reports that there is no gas in the car even after filling up. The engine light also comes on because of this and causes issues with the car. It is out of warranty and the deal says it is could be any number of problems with the fuel system that would cost over $800. It is very scary because of the warnings that come on the car. It started after filling with gas and before would be normal after driving about 20 miles. Now it is constant. When I first start the vehicle it works fine and tells me the range, but as soon as the car is in motion it goes back to empty. Have replaced gas cap and other things as suggested, but the problem is now constant and at times while driving I can smell gas very strong. It lasts for a about 10-15 minutes and is frightening, the dealerships says it could be the pressure in the gas tank. It is very scary and very expensive for an issue they are unsure of. I request you investigate this because it appears to be a problem that the dealership knows about and refuses to do anything about unless we spend the money for them to fix something they are not sure of and have been given about a 50% chance the problem returns.

My 2004 Chevrolet Trailblazer 4wd has 41,000 miles on the odometer. Recently the service engine soon (ses) light became illuminated. Personal inspection of the vehicle revealed a small crack in the plastic fuel tank. The crack was located at the "weld" or joint where the plastic fuel fill pipe connects to the tank. This fill pipe also houses the fuel tank inlet check valve (icv). As my vehicle was past the three-year - 36,000 mile warranty period I attempted to glue the leaking crack. This held for a few weeks, the ses light went out and there was no odor or appearance of gasoline leaking from the area. Eventually, though, the leak returned, evidenced by the ses light illumination and gasoline leaking from the repaired area. Another repair attempt was made and is currently under observation. This exact problem appears to be detailed in general motors document id# 1985459; subject: special coverage adjustment - fuel tank inlet check valve fracture #07099 - (06/07/2007). This referenced document only pertains to 2002-2004 Chevrolet Trailblazer ext and GMC envoy xl, both longer wheelbase models than my standard LS model. Upon my discovery of this manufacturer known problem with this vehicle model, I took my Trailblazer to the local Chevrolet dealer today. The service consultant said he was not familiar with my problem and was unable to access the computer database for any relevant documents for my vehicle. He did take a copy of the above referenced special coverage adjustment document and promised a return call tomorrow.

There was a smell of gas, so I took it in to the dealer after they said it should be covered. They found rotted fuel module and hoses, removed fuel tank found fuel sending unit rotted,lines and hoses. . Replaced sending unit lines and hoses. Mdle kit 3. 107 part# 19206122 . . Pipe 3. 163 part#15174333. . . Pipe 3. 163 part#15015511. . . Sensor 3. 107 part#16238399. . Now tell me it would have been covered if I brought it in earlier, I only just got the notice to have it looked at , so how could I have brought it in earlier.

Service engine soon light on when we bought it. Had it checked into, error code indicated a leak in fuel system. Suggested a new gas cap. That was not the problem. There is a crack in the nipple on the gas tank where the fill pipe hose connects. Need to replace the whole tank. Appr. Cost just for the tank $500 plus labor.

Service engine soon light came on. Took it to auto zone and computer diagnosis was evap emission leak, small. Code:p0440. This happened twice over 2-3 week period. Replaced gas cap, that was not the problem. Light came back on. Took to dealership garage, I was told that I had a significant leak in my gas tank, at the filler neck, would cost $900 to fix it. Thing is, I had been driving this car around for over 3 weeks with my 2 small children in it with the possibility it could have caught on fire! how scary is that? dealership said it was not safe to drive due to possibility of catching fire. Contacted gm consumer service, awaiting their return call. They didn't seem interested in helping me. I know previous yrs (2002, 2003, and early 2004 models) have the same problem and was covered by gm or were recalled. I have never received a recall notice. I think it is suspicious that I have the same problem as previous yr models and I have only 85,000 miles on my car.

"service engine soon" light came on. Took it to dealership. Was told that the fuel cap was bad and there was a crack in the fuel tank. Replaced both parts costing $946. 73.

Around 50k miles the service engine light came on. I took the vehicle to the dealership. I was asked if I had recently got gas, when I replied yes, he told me to tighten the gas cap and the light would go if in a few days. The light did go off but the mechanic never documented anything about my visit. Several weeks later the service engine light came on again. Thinking that it was the same situation I tightened the gas cap and did not go back to the dealership. This time the service engine light did not go off. I took the vehicle to an independent garage to get it checked out and the result was a malfunction in the fuel system. Often times I smell gas vapors especially after fueling. Recently I was parked on a hill and gas was dripping from my tank. Local dealerships act as if they have never heard of the problem. My warranty has expired.

Check engine light came on three times within the first month and a half I owned the used 04 Trailblazer. It seems common from what most people posted on the internet that this problem occurs anywhere from 35 - 55k miles. The gas tank would constantly release an odor and I would get dizzy every time I drove the truck. I took it in to the dealer and they said it was just a leak in the gas cap and that it needed to be replaced. Once the warranty expired (one week later), the s. E. . Light came on again and the dealer service department stated that there was a crack in the neck of the tank and that it needed to be replaced. I picked it up today after it was replaced and totaled to $1,430. Gm knows about this problem and hopefully the letter that I have written to them will solve this issue and that I will either be reimbursed or compensated somehow for lost work and interest paid on this bill.

The contact owns a 2004 Chevrolet Trailblazer. The contact was driving approximately 30 mph when the check engine light illuminated. The vehicle was taken to a local repair shop where the fuel cap was replaced. The failure recurred within one year. The vehicle was diagnosed and again, located the failure at the fuel cap. The contact stated that the failure recurred three times in which each time; the fuel cap was replaced as the remedy but to no avail. The vehicle was then taken to an authorized dealer and he was advised that the fuel tank exhibited a hairline fracture. The vehicle was then taken to the independent mechanic for repairs in which the fuel tank was replaced. The manufacturer was contacted and a complaint was filed. The VIN was unavailable. The failure and current mileage was unknown.

The contact owns a 2004 Chevrolet Trailblazer. While driving at various speeds, the check engine light illuminated and the message center informed the contact to tighten the gas cap. When he attempted to tighten the gas cap, he noticed a thin crack in the filler neck. When he fills the gas tank, there was some leakage from the crack of the filler neck. The contact has taken the vehicle to the dealer, but it was not serviced because the warranty was expired. The current mileage was 34,000 and failure mileage was 33,000. Updated 04/22/08. The pipe to the gas tank was composed of plastic. It has a crack about 1/2 inches long at the gas cap area, thus allowing vapors to escape the tank. Updated.

2004 chevy Trailblazer. Gas leak where the filler neck connects to the tank. I have seen many, many of these on the forums. Gm has a bad design here.

Fuel spillage during refueling; during refueling the fuel will spill out from behind the top of the tank behind the wall. Happened since vehicle has been owned.

Gas tank leak on my 2003 Trailblazer ext, found a leak from my gas tank.

I have a 2002 Trailblazer ext and the gas tank leaks at the filler tube connection.

I have a 2004 chevy Trailblazer and from day one I've had problems with gas overflowing out of my vehicle when pumping gas in to it. I'm not trying to top off the tank, at the first click I stop pumping and gas overflows outside of the vehicle all over my car, my feet and legs and the ground. Sometimes I don't even get the warning click that it's full. It doesn't do it all the time so when I've taken it to my dealership they say they can't duplicate the problem. I've met other Trailblazer owners at the pump and they say they have the same problem. This doesn't seem safe or environmentally sound. I have had the vehicle for 4 years and have tried many different gas stations/pumps.

When filling up with gas, it spews from the tank when gas nozzle is removed. It does not matter how much gas is in tank & happens even when tank is not being topped off. Also when filling, you must constantly reposition the nozzle because of gas build up in tank line will inadvertently cause pump to turn off. This has happened on numerous occasions, however last night was the final straw, Trailblazer had a quarter tank of gas, after pumping in less than a gallon, nozzle/pump started its clicking/auto shut off. I removed the nozzle to reposition it as usual & upon removal of nozzle gas sprayed (like spraying from a hose nozzle)from the tank as if under pressure. I was completely covered with gas from the waist down, I'm not talking about a light spray but soaked through my clothes to the skin with gas. Based on the amount of gas left on the ground I estimate that 2 or 3 gallons sprayed from the tank, the only way it was stopped was by putting the cap on. Although not seriously injured I am now covered in a rash from the gas from the waist down.

Filled my vehicle up with gas and my gas gauge reads low fuel. Poor equipment is the cause this happened on a new SUV and they should fix them. The cost is over $500. 00 dollars I understand that maintenance is my responsibility but a new truck should not have issues such as these. Also sometimes the transmission goes in neutral when I'm in drive and I lose power. The tech's cant find what the problem is. Also a code for the purge valve is on and the dealer cant find the problem. Please help .

2003 chevy Trailblazer ext. Service engine light went on about a month ago. Service at dealership said we needed a new gas cap. Replaced gas cap and light came back on. Continuous smell of gas within the cabin and outside. Can't fill tank all the way or smell gets wore. Can't park in garage fear of gas build up and explosion.

On my first day from the lot purchasing a 2003 Chevrolet Trailblazer, gas runs from the fuel tank when I fill up. After seeing all the complaints with the same problem, why is there no recall for this?.

I have a 2003 Trailblazer ext. Just got it from my in-laws, only 21k miles on it. Gasoline vents on the ground when filling the tank full. The check engine light remains illuminated. I counted more than 20 complaints just like mine on the NHTSA complaint list. Example odi id numbers are 10191706, 10190967, 10188345, 10187405, 10186556, 10185694, 10184336, 10183773, 10182724, 10182384, etc. I assume it is a cracked filler neck. I called gm customer service. They seemed helpful and gave me a case number, but advised me to go to a gm dealer for an official diagnosis before they can proceed with helping me further. No promises at this time. I assume I'll have to pay for the diagnosis. This is a dangerous malfunction, it causes fumes, odors, and puddles of gasoline beneath hot vehicles.

2003 Chevrolet Trailblazer ext leaking fuel at filler neck/fuel tank. Check engine light continued to come on with variations in duration after reset. Code indicated small fuel leak. Strong odor of fuel surrounding vehicle, and sometimes came inside of vehicle after fill up. Finally, discovered leak after completely filling tank and parking on hill. Gas poured out.

I am being told that my 2003 chevy Trailblazer has a cracked gas tank and has been leaking fuel. We have noticed a strong gasoline odor from the outside of the vehicle for a few weeks. Apparently, chevy created a 'special policy' when this issue occurred for its 2002 Trailblazers, but I am concerned that no attention is being given to the 2003 models. My dealership is replacing the gas tank which normally would have cost approx $1300, however, to get this deal, they are requiring me to pay for the 50k suggested maintenance on the vehicle at a cost of $475. There has been no injury or accident to myself as a result of this defect, but I feel that it is important enough to warrant investigation since this has also occurred in previous models. Also, in previous models chevy paid for all of the repairs without requiring the owners to spend money on 'suggested maintenance'. The service bulletin number from chevy for the 2002 models is TSB 05012.

Found a crack in the filler pipe leading to the gasoline tank on my 2002 Trailblazer ext. First started smelling gasoline, then loss of gas mileage and then check engine soon light remained on.