Problems with 2004 Chevrolet Corvette FUEL SYSTEM, GASOLINE

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

Strong smell of fuel and occasional dripping of gas. i am on vacation in illinois from arizona and am now facing a $1500 bill just to get back home. i see gm doesn't care so maybe ford would like a vette. *tr

Fuel leak on 2004 chevrolet corvette. strong gasoline odor inside the vehicle. tank leakage if filled for $20 or more of gasoline. *tr

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. *tr

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. *tr

Strong smell of gas whenever i fill up. unable to locate any leaks right now. strong gas odor will last until i drive for 50 miles or more. *tr

Gasoline smell/leak when you fill the tank on my 2004 chevrolet corvette. there should be a recall as this is a common problem. *tr

Fuel smell when filling car with gas odor is also in car. *tr

Smell of gasoline when stopped and after car is parked overnight. updated 08/04/10 *bf 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 *tr

I kept getting strong fuel odors in my garage but never could locate the leak. i went to fill up and gas ran down the pavement on the driver side. i took the car to the dealership and they informed me that the fuel tank had a crack in at and it spilled when i filled up directly over the exhaust pipe. the tank was replaced with a new one. the old tank was left at the dealership. *tr

2004 chevrolet com.edition z06 corvette. purchased in sept 2008 with 5500 miles from the original selling dealership. now with approx 9800-10,000 miles a fuel leak has developed when fueling the car up. at approx +1/2-3/4 tank fuel spills out under the car on the drivers side. this year saw an installation of a new stainless fuel crossover line between the tanks. they have been notorious for leakage along with the driver's side tank in the area where the crossover line couples to the tank. along with what i consider a major safety risk due to the possibility of fire, (the exhaust and fuel tank are in very close proximity) this also must be an epa/emission violation from escaping fumes, vapors and fuel. this vehicle has been painstakingly maintained and is in as new condition (10,000 miles) this is a defect from gm and due to the inherent possibility of loss of life and/or property damage should be recalled or at least repaired by an authorized gm dealership. this vehicle does have a 80,000 mile emission warranty under which this falls. *tr

Very strong gasoline smell when car is parked in garage. *tr updated 07/26/10.*jb

Strong gasoline smell from drivers side passenger compartment upon gas fill. *tr

Fuel leak in crossover pipe was discovered after strong fumes in car and gas leaking under car. this has happened on my car plus one other of the same model year and purchased at the same time.. *tr

Own a 2004 corvette z06 with 66,000 miles. at about 63,000 started to smell gas fumes. bought a new gas cap but still smelled fumes. took it to a certified corvette mechanic and found the leak to be the left fuel tank at the crossover pipe. he replaced both fuel tanks and cross over for around $1900. my brother also owned a 2004 corvette with about the same mileage and had the same problem. he took his to a dealer and they replaced both fuel tanks and crossover for around $2700. *tr

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. *tr

If you go the corvette forum online you will see an ongoing discussion on 2004 corvettes with fuel tank/crossover pipes venting fumes and or leaking. it seems limited to the 2004 model and the problem is cracking fuel tanks or bad crossover pipe seals that require tank replacement to repair. they are charging upwards of $2,400.00 to repair this! since it vents raw fuel and or fumes into the air i feel this should be a recall for safety reasons besides the emission violation! this is a very common problem on this model and should be looked into before some ones car explodes! *tr

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. *tr

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 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. *tr

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. *tr

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. *tr updated 003/30/10 *bf updated 10/05/10

Tl*the contact owns a 2004 chevrolet corvette. after gasoline was placed in the vehicle and it had been parked for a while, the contact noticed that all of the fuel was leaking underneath the driver's side of the vehicle. the dealer stated that the fuel level sensor was the cause of the failure. the contact stated that the original owner of the vehicle had this component previously repaired and it should not be failing again. the vehicle has not yet been repaired because she feels that the manufacturer should have repaired it correctly while it was under recall. the current and failure mileages were 5,800.

My 2004 corvette z06 leaked gasoline from the hose that interconnects both fuel tanks. the tanks and connector were replaced by extended warranty but they were replaced with one of similar identical design. after doing some research it seems like this was not a one case even m any 2004 owners report the same issue. considering the risk of the problem a more appropriate redesign should be performed. *tr

Left side fuel tank leaking gas. *tr

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. *tr

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. *tr

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. *tr

Problem 1: gasoline smell with leak and ultimate failure of valve to transfer fuel from one tank to another. occurred continually with fuel tank registering full to 3/4 tank then dropping to empty and vehicle appeared to be out of gas (would not run until fuel added to tank). solution: took vehicle to chevrolet dealership for repairs. repair invoice states: "replaced l/s gas tank and pump and sender and replaced r/s fuel pump and sender. check fuel gauge and tanks found l/s fuel tank leaking at top of tank. weld also found fuel level sensors open circuit and fuel system not transferring fuel from tank to tank. retest after repairs. ok" problem 2: a/c display lights do not illuminate and controls are difficult to see at night. solution: took to chevrolet dealership for repairs. repair invoice states: "controller has internal failure, replaced controller." *tr

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. *tr

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. *tr

Noticed a gasoline smell getting out of car. puddle of gas on ground under fuel tank. dealer changed out fuel tank. service writer said the cross over pipe had a deformed fitting. *ak .

In 2007 i was filling my car up with fuel. when i got home i noticed a leak on my garage floor. this happened only when i filled over half a tank. after finding a knowledgeable mechanic to handle this job, they removed the transaxle to expose the fuel tanks, we realized that it was a leak in the cracked connector of the left hand tank, where it joins with the crossover pipe. i had to order a new lh tank and a crossover pipe from the us and after huge expense and months without my car, we finally fixed the problem. now it seems this is a common problem arising in the 04 corvettes and needs to be addressed before a fuel fire fatality happens. *tr

I smelled gas in my garage for approximately 1 week but found no leaks. while filling up at gas station i notice a large puddle forming under car and saw gas leaking from tank. dealer said gas leak was found in gas tank, crossover fuel line and two other fuel lines. very dangerous situation. dealer said manufacturer defect in parts. took 10 days to repair as the first time tank was replaced there was no fuel pressure and had to be redone. *nm

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. *nm

Noticed puddle of fuel under car aft of driver door. took to dealer who replaced crossover pipe which they said was cracked. under original warranty. *tr

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 *tr

While the vehicle was parked, the consumer noticed that fluid was leaking from underneath the vehicle. the vehicle was taken to the dealer for inspection. the mechanic informed the driver that the gas tank needed to be replaced. please provide further details. *jb

I have a brand new 2004 corvette 1 1/2 months old with only 1341 miles on it. while driving home in rush hour dallas traffic on a very busy fast moving road, my engine died in the middle of the road. i could not restart the car & was in a very serious situation risking the possibility of being rear ended. luckily a policeman came by and parked behind me to shield me from the traffic. if i had been on the freeway, i could have been killed. the gm dealer where i purchased the car (ray huffines chevrolet of plano) is acting like it is no big deal. they said it is the fuel pump & they will replace it when they can get a fuel pump and if it happens again, to bring it back. if it happens again & i would be on the freeway, i more than likely would not be alive to take the car back in. i drive 50+ miles a day to & from work mostly freeway driving. i feel the dealership is trying to put my life in jeopardy. i want my money back and out of this car. in researching, i have found that 127,000 2004 corvettes have been recalled for steering problems. i was never advised of this when i purchased this car or of any fuel pump issues. i have purchased a brand new car every 3 years for the last 20 years & i have never had a problem like this, especially with a brand new $50,000 car and i have owned 280zx, 300zx, rx7, supra, and lexus. i need help from gm or someone to resolve this. *jb

Smell gas odor outside the car, mostly on the driver side. gas leaks found by the dealership on the driverside fuel tank, seal on the fuel pump, and the interconncting hoses for both tank. all parts replaced.*ak

I have a 2004 corvette coupe and i am having a gas smell or leak from my crossover connector on my gas tank. after reading many articles from other corvette owners i know that this is a serious problem and should be a recalled item. this is a safety hazard as the gas tank and leak comes right over my dual exhaust and could cause a fire.

Check engine light warning. right side fuel tank leaking. *tr

Gas tank leak .. brand new car 2004 corvette... gas was leaking from the crossover pipe ( what dealer said ) needed to replace this and the left side gas tank. took 25 days to fix no parts. been told by several people that this is fairly common. this leaked about a gallon or more on my garage floor could have been a very dangerous situation as i have a gas hot water heater and there is a pilot light. fumes were considerable when discovered. also leaked gas while driving with dripping and noticeable gas. *ak