Originally Posted by travisnd

What about the later production 2003s that got the updated fuel system as well? Why are they not covered?

Originally Posted by 2004c5blackcoupe

2004 model year vehicles were manufactured in 2003/2004.
It was determined that the defective tanks were manufactured on
09-30-2003 and 01-07-2004 affecting vehicles produced 10-22-2003 through 03-19-2004 affecting VIN range 45110258-45125500. The other vehicles outside of this range were manufactured with new tanks from a different vender which hopefully are not defective as well.

Reference: page 13
http://nhthqnwws112.odi.nhtsa.dot.go...015-40760P.pdf

Originally Posted by 2004c5blackcoupe

Pe 10015 GM 6-30-2010 Attachment 1 GM Investigation

http://nhthqnwws111.odi.nhtsa.dot.go...015-40764P.pdf

See pages: 96,123,149,158,166

Page 96 Fuel Leaks-Root Cause:

"The crossover quick connect is an injection molded component molded at Viking Plastics using a material provided by PolyOne Corporation. 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."

"TI suspects that the components that should have been scrapped, were re-introduced into production on at least two other occasions."

Originally Posted by 2004c5blackcoupe

"By design, the right hand tank is mounted tightly to its surrounding surfaces. The left hand tank has a 12mm gap to its mounting surfaces that is filled with foam isolators. The purpose of the foam is to dampen noise related to fuel pump operation. This gap allows the LEFT HAND TANK TO MOVE MORE THAN THE RIGHT HAND TANK during driving maneuvers and as a result, THE LEFT HAND QUICK CONNECTOR EXPERIENCES MORE LOAD than the right hand. Additionally, since there is always more fuel in the left hand tank than right hand tank, even when both are full, THE LEFT HAND QUICK CONNECTOR WILL EXPERIENCE HIGHER LOADS."

Also, of the total warranty claims, the left hand fuel tanks were replaced 89% of the time vs. 11% for the right.

http://nhthqnwws112.odi.nhtsa.dot.go...015-40760P.pdf
see page 14

If the foam isolators compress over time then the left hand tank would move even more causing excessive stress on the connector eventually causing a crack/failure/leak.

I believe this design is part of the problem in addition to defective connector.

Don't you guys think that the left hand tank should be more secure, perhaps strapped down or more foam to prevent movement? You can pull almost 1 g in a hard turn, not to mention 0-60 in 4 seconds!

If so, then GM needs to do a re-design of the mounting of the left tank.

Anyone?

Originally Posted by 2004c5blackcoupe

Thanks Ratmotortom for posting in "2004 cracked crossover connector smells thread"!!!

ratmotortom has just replied to a thread you have subscribed to entitled - Fuel leak 2004 cracked crossover connector smells - in the C5 General forum of Corvette Forum.

This thread is located at:
http://forums.corvetteforum.com/c5-g...-new-post.html

Here is the message that has just been posted:
***************
Read this !!!!!


#10150: Special Coverage Adjustment-Fuel Tank Quick Connector Leak - (Aug 13, 2010)


Subject: 10150 - Special Coverage Adjustment - Fuel Tank Quick Connector Leak


Models: 2004 Cadillac XLR

2004 Chevrolet Corvette




--------------------------------------------------------------------------------

Condition
Some 2004 model year Cadillac XLR and Chevrolet Corvette vehicles may have a fuel tank leak at the quick connectors that are used to link the left and right fuel tanks. The customer may notice a fuel odor while the vehicle is being refueled, driven, or after it is parked. If the leak becomes large enough, a small amount of fuel may be observed dripping on the ground. The leak may also result in a diagnostic code being set and the illumination of the Check Engine light on the instrument cluster.

Special Coverage Adjustment
This special coverage covers the condition described above for a period of 10 years or 100,000 miles (160,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership.

Dealers are to replace the leaking fuel tank. The repairs will be made at no charge to the customer.

For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after August 16, 2010, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to August 16, 2010, must be submitted to the Service Contract provider.

Vehicles Involved
Involved are certain 2004 model year Cadillac XLR and Chevrolet Corvette vehicles built within the following VIN breakpoints:

Year
Divison
Model
From
Through

2004
Cadillac
XLR
45600796
45602844

2004
Chevrolet
Corvette
45110258
45125500


Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link on the Global Warranty Management application within GlobalConnect. Special Coverage Adjustments are displayed in the Applicable Warranties section.

Parts Information
Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A).

Part Number
Description
Qty/ Vehicle

25899601
Tank, Fuel (LH)
1 (If Req'd)

10337582
Tank, Fuel (RH)
1 (If Req'd)

89047640
Insulator, F/Tnk (LH)
1 (Req'd when replacing left fuel tank)

15223882*
Hose, Fuel Feed
1 (If Req'd)

10337583*
Pipe, Aux Fuel Feed & Rtn RR (LH)
1 (If Req'd)

10337581*
Pipe, Aux Fuel Feed & Rtn RR (RH)
I (If Req'd)

21008100**
Gasket, F/Pmp
1 (If Req'd)


* Less than 30% of vehicles requiring tank replacement will require this.

** Less than 25% of vehicles will require this.

Customer Notification
General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter included with this bulletin - actual divisional letter may vary slightly).

Service Procedure
Determine if the left or right fuel tank is leaking. Refer to Fuel Tank Leak Test in SI for diagnostic information.
• If the left or right fuel tank is leaking, proceed to Step 2.

• If the fuel tanks are not leaking, no further action is required.

Remove the left or right fuel tank from the vehicle. Refer to Fuel Tank Replacement - Left Side or Fuel Tank Replacement - Right Side in SI.
Install the new fuel tank. Refer to Fuel Tank Replacement - Left Side or Fuel Tank Replacement - Right Side in SI.
Claim Information
1. Submit a claim using the table below.

Labor Code
Description
Labor Time
Net Item

T5787
Perform Diagnostics - No Tank Replacement Req'd
0.0-0.3
N/A

T5785
Replace One Fuel Tank
7.5
N/A

Add: Replace Both Fuel Tanks
2.0

Add: Diagnostic Time
0.0-0.3

T5786
Customer Reimbursement (not for use by US GM dealers)
0.2
*


* The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer.

Customer Reimbursement - For US
All customer requests for reimbursement for previous repairs for the special coverage condition will be handled by the Customer Assistance Center, not by dealers.

A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter.

Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form.

Customer Reimbursement - For Canada and Export
Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by August 31, 2011. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 160,000 kilometers, whichever occurs first.

When a customer requests reimbursement, they must provide the following:

- Proof of ownership at time of repair.

- Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair.

If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership.

August 2010
Dear General Motors Customer:

As the owner of a 2004 Cadillac XLR or Chevrolet Corvette, your satisfaction with our product is very important to us.

This letter is intended to make you aware that some 2004 Cadillac XLR and Chevrolet Corvette vehicles may have a fuel tank leak at the quick connectors that are used to link the left and right fuel tanks. The customer may notice a fuel odor while the vehicle is being refueled, driven, or after it is parked. If the leak becomes large enough, a small amount of fuel may be observed dripping on the ground. The leak may also result in a diagnostic code being set and the illumination of the Check Engine light on the instrument cluster.

Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your vehicle has the condition as described above.

What We Have Done: General Motors is providing owners with additional protection for the fuel tank connectors. If this condition occurs on your 2004 model year Cadillac XLR or Chevrolet Corvette vehicle within 10 years of the date your vehicle was originally placed in service or 100,000 miles (160,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the condition described above is not covered under this special coverage program.

What You Should Do: Repairs and adjustments qualifying under this special coverage must be performed by a General Motors dealer. You may want to contact your GM dealer to find out how long they will need to have your vehicle so that you may schedule the appointment at a time that is convenient for you. This will also allow your dealer to order parts if they are not already in stock. Keep this letter with your other important glove box literature for future reference.

Reimbursement: The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the special coverage condition. Your request for reimbursement, including the information and documents mentioned on the enclosed form, must be received by GM by August 31, 2011.
***************

Originally Posted by 2004c5blackcoupe

NHTSA PE10015 Investigation Closed

http://nhthqnwws112.odi.nhtsa.dot.go...10015-7965.PDF

Here is the kicker:
"GM does not believe the cracks represent an unreasonable risk to motor vehicle safety..."

So instead of a RECALL GM will fix your vehicle only IF it is leaking.
Thats great unless you fill your tank, park it in your garage, go to sleep and your house catches on fire!

Any attorney would love to get a case like this.

GM admits there is a defect, but won't issue a recall. We will only fix it if it is leaking!

Looks like NHTSA dropped the ball on this one.

Originally Posted by 6GenVettes

Are you having the fuel vapor smell issue with your 2004?
Note that GM's voluntary 10-year service fix has expired and you are now on your own.
In lieu of the voluntary 10-yr fix there was no recall.

If U have the issue, read what C6 (Sticky) continues to do about this carry-over design.
http://forums.corvetteforum.com/show....php?t=3563123
And if U missed it, this was the original thread dealing with the fuel leak
http://forums.corvetteforum.com/show....php?t=2430894
(now at 35 pages but not a sticky any longer)

With that said, perhaps these two C5 threads need to become a Sticky under C5 Discussion/Tech for the same reason that C6 has this active safety conversation.

Originally Posted by EPTR6

Not to beat a dead horse here, but looking a C5 that falls into the range of VIN's. Current owner has not experienced any of the symptoms listed on the earlier posts. Anyone care to speculate on the percentage of C5's effected? Seems to be a crap shoot on buying one in the VIN range? thanks all!