Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety. Notes: The 2006 Cobalt continued to carry the torch first lit by the 2005 model year. To be clear, that torch is burning bright with widespread power steering issues, electrical curiosities and a dangerous ignition switch defect which led to a massive recall by GM. This isn’t a great torch to carry.

The 2006 added it’s own special flare with gas leaks due to cracks in the “return portion of the modular reservoir assembly.” A recall of 2006 Cobalts was issued to fix the problem, but only to vehicles sold in or current registered in Arizona and Nevada, leaving other owners to pay for repairs themselves.

Between this car stalling while driving, giving owners fits with power steering failure and having it be a potential tinderbox because of gas leaks, we felt we had no other option than to award it our “Avoid Like the Plague” badge.


really awful
Crashes / Fires:
3 / 2
Injuries / Deaths:
2 / 0
Average Mileage:
66,219 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2006 Chevrolet Cobalt fuel system problems

fuel system problem

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2006 Chevrolet Cobalt Owner Comments (Page 6 of 8)

« Read the previous 20 complaints

problem #57

Apr 022011


  • 86,000 miles


My husband and I had been smelling gas coming from our car for a while. We took it in to get the brakes replaced and they told us that we had a fuel pump leak and would not work on the brakes until it was fixed. The cost to fix is well beyond our means and now we are going through a half a tank of gas every 3 days for less than 30miles of travel. There was a recall on the fuel pump for this problem in several other states, not including the one we live in. We have a very young child and one on the way and do not want anything bad to happen.

- Denver , CO, USA

problem #56

Feb 212011


  • 56,000 miles
My vehicle began to smell like gas but there was no sign of a leak. A friend who is also a fleet technician, looked at the vehicle for me and found there was a small leak near where the fuel lines connect to the fuel sender at the top of the gas tank. In trying to get an estimate of the cost of repairs, I found that numerous people have the same problems with this make, model and year. There is even a recall for this vehicle 09V419000, but only if I live in Arizona or Nevada. It seems we are being penalized for not purchasing our vehicle in the right state. I found the numerous complaints at this site:

- Little Elm, TX, USA

problem #55

Nov 012010


  • 60,200 miles
The contact owns a 2006 Chevrolet Cobalt. The contact stated that whenever the vehicle was stationary or in operation, there would be an extremely strong odor of fuel inside and outside of the vehicle. The vehicle was taken to an independent mechanic where they detected fuel leaking from the emission valve. The contact was waiting for a response from the insurance company in order to cover the repair expense. The failure mileage was approximately 60,200.

- Homosassa, FL, USA

problem #54

Dec 112010


  • 52,000 miles


The contact owns a 2006 Chevrolet Cobalt. The contact stated that the fuel line was fractured and leaking abnormally. The contact located a recall for the failure under NHTSA campaign id number: 09V419000 (fuel system, gasoline: Delivery: Fuel pump but was advised by the manufacturer that the vehicle was not included in the recall. The manufacturer stated that a representative would be sent to further inspect the nature of the failure. The VIN was unavailable. The failure mileage was 52,000.

- Louisville, KY, USA

problem #53

Jan 212011


  • 80,000 miles
The contact owns a 2006 Chevrolet Cobalt. While the vehicle was parked the contact smelled a strong gasoline odor. The vehicle was taken to an independent mechanic who stated that there was a crack within one of the plastic fuel lines. The fuel lines were repaired. The manufacturer was also notified and the contact was told that the vehicle was not included in NHTSA campaign number 09V419000 (fuel system, gasoline:delivery:fuel pump). The failure and current mileages were 80,000.

- Louisville, KY, USA

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problem #52

Dec 152010

Cobalt 4-cyl

  • 72,000 miles
I have a 2006 Chevy Cobalt. It has been leaking gas and not starting for about 2 weeks. I took it to the dealer and they said it was the fuel pump which got recalled but only if you live in nv and AZ.

- North Lauderdale, FL, USA

problem #51

Jan 032011

Cobalt 4-cyl

  • 89,000 miles


While driving my vehicle decelerated to 5 mph and a engine power light came on. I took it to a local shop and the throttle actuator control error came up. I been told this is occurring a lot in american made vehicles.

- Omaha, NE, USA

problem #50

Nov 102010

Cobalt 4-cyl

  • 72,000 miles
Failure on the fuel pump, leaking under the car alot dangerous fumes does not start at times and when it does leaks alot of gas and smells really strong and then stops suddening. So will not move it due to its danger of the gas leak.

- Austin, TX, USA

problem #49

Dec 262010


  • 35,700 miles
The contact owns a 2006 Chevrolet Cobalt. The contact stated that there was a strong smell of fuel from the passenger side of the vehicle. The dealer stated that the vehicle was included in recall 09V419000 (fuel system, gasoline: Delivery: Fuel pump). The current and failure mileages were 35,700.

- Cary, IL, USA

problem #48

Nov 172010

Cobalt 4-cyl

  • 77,000 miles
Campaign 09V419000 states that certain VIN numbered 2006 Chevy Cobalts have a fuel pump module that may crack and break and leak gas which could cause a fire. I took my car into the dealership and now GM is saying my car doesn't fall under the VIN numbers. My car does fit between the breakpoints. I am having to pay for a new fuel pump which is very expensive. My car has been leaking gas and it was because of this exact cause and now GM won't fix it.

- Sierra Vista, AZ, USA

problem #47

Oct 022010


  • 78,000 miles


The contact owns a 2006 Chevrolet Cobalt. The contact stated fuel was leaking onto the exhaust pipe, which could cause a fire to occur. The failure also caused the vehicle to stall. The dealer inspected the vehicle and stated that the modular reservoir assembly failed causing a fuel leak that was recalled under campaign 09V419000, fuel. The manufacturer told the contact that the vehicle was not included in the recall. The failure mileage was 78000. The current mileage was 89,000.

- Lakin, KS, USA

problem #46

Aug 222010


  • 83,000 miles
The contact owns a 2006 Chevrolet Cobalt. The contact stated that the vehicle was leaking fuel from the fuel tank. The contact believed the failure to be within the fuel pump module. The contact believed that the vehicle was included in recall 09V419000 (fuel system, gasoline: Delivery: Fuel pump). The vehicle had not been inspected or repaired. The failure mileage was approximately 83,000 and the current mileage was approximately 86,000.

- Indianapolis , IN, USA

problem #45

Oct 192010


  • 40,904 miles
We experienced the same problem described in NHTSA campaign number 09V419000 on our 2006 Chevy Cobalt (VIN [xxx]). we smelled a strong fuel smell and took it to the dealer (sands Chevrolet glendale AZ) for repair under the recall. We were denied service under the recall even though the plastic supply port was cracked and leaking fuel as described in the recall. We were charged $673.48 to repair the dangerous defect plus $134.24 for another fuel filter they said we needed. Due to the potentially deadly defect we had no choice but to pay for the repair. If the dealer was telling the truth then it seems the scope of the recall needs to be expanded. Please look into this. We don't want to see drivers of the 2006 Cobalt exposed to this potentially deadly defect and fire hazard. Information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- Alpharetta, GA, USA

problem #44

Oct 082010


  • 137,000 miles
The contact owns 2006 Chevrolet Cobalt. While driving 70 mph the fuel gauge rapidly started moving down and fuel was leaking out of the vehicle. She had to drive onto the emergency lane and call a tow truck. The vehicle was towed to her residence where a mechanic inspected it and found a leak on the fuel pump hose. The manufacturer was contacted who stated there are no recalls and offered no assistance. The failure mileage was 137,000.

- Bryant , AR, USA

problem #43

May 032010


  • 96,000 miles
The contact owns 2006 Chevrolet Cobalt. The contact stated that the fuel pump was leaking fuel onto the manifold. The dealer stated that it was directly related to recall campaign 09V419000, which deals with the fuel pump, but her vehicle was not listed in the recall. The contact was concerned that the failure could cause a fire to occur. The failure mileage was 96000 and the current mileage was 98000.

- Lafayette, IN, USA

problem #42

Sep 152010

Cobalt 4-cyl

  • 60,000 miles
The contact owns a 2006 Chevrolet Cobalt. The contact stated that the vehicle was taken to a local repair facility for a routine oil change when the contact was informed that there was an abnormally strong gasoline fuel odor emitting from the vehicle. The mechanic discovered a fuel leak and performed a diagnostic. The mechanic advised the contact that the fuel sending unit was fractured at the top of the fuel tank. The vehicle was repaired. The failure and current mileage was 60,000. Updated 01/04/11 the consumer stated the same problem he experienced a recall was issued. However, his VIN was not included. Updated 01/10/11

- Stuben Hill, OH, USA

problem #41

Sep 212010


  • 50,036 miles
Gasoline leak from fuel tank at fuel pump, 2006 Chevy Cobalt registered in New York state.

- Clifton Park, NY, USA

problem #40

Aug 262010


  • miles
The contact owns a 2006 Chevrolet Cobalt. She was not clear on how the failure began because someone else was operating the vehicle. The driver began to smell gasoline coming from the vehicle while driving at any speed or while parked. The vehicle was taken to an independent mechanic where she was informed there was a fuel leak and it was in the process of being repaired. The failure and current mileages were unavailable. The VIN was unavailable.

- Alvin, TX, USA

problem #39

Sep 012010

Cobalt 4-cyl

  • 72,500 miles
Upon exiting vehicle, noticed extremely strong smell of gas on 9/1/10. Gas smell did not dissipate, and in fact got stronger over the period of one week. Noticeable inside and outside the cabin. Mileage at time of failure was approximately 72500. Spoke with dealer about problem, told that it did not fall under current recall conditions and there was nothing they could do. Had mechanic look at it, who confirmed that the fuel pump module needed replaced the lines attached to it had cracked and was leaking fuel on the top of the tank. Extreme fire hazard. Repairs were $760. Fuel pump module was replaced after diagnostics and having the tank dropped. Part available. Exact description of problem falls under the NHTSA campaign 09V419000 recall. Car is not in recall state, but issue has been indicated to be related to high heat. Heat in current state (wv) has been 90+ degrees for more than 2 months. Dealer did not look at recall, only at the vis which did not include my car's VIN, apparently. This is an extreme safety issue, and should be expanded to include all 2006 Chevy Cobalts who have similar parts in their car. The state specific recall has been indicated in numerous complaints abundant on the internet to be a false, as people are affected nationwide. GM claims that safety is their number one concern, but they do not (according to the rep I spoke with ) have an ongoing investigation into whether they should expand this recall into other states. This is appalling and needs looked into by someone who has the consumer's safety in their best interest.

- Martinsburg, WV, USA

problem #38

Aug 312010


  • miles
Car smelled like gas all the time, wouldn't start easily when cold. Gas was leaking from the top of the fuel pump. Fuel pump was replaced.

- Tyler, TX, USA

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