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definitely annoying
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
38,802 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.

2004 Chevrolet Corvette fuel system problems

fuel system problem

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2004 Chevrolet Corvette Owner Comments (Page 2 of 4)

« Read the previous 20 complaints

problem #56

Sep 152008

Corvette 8-cyl

  • 130,000 miles


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."

- Grapevine, TX, USA

problem #55

Aug 202010


  • 41,000 miles
2004 Chevrolet Corvette: This problem became evident after a strong gasoline odor and gasoline vapors began to be noticeable in the passenger cabin. Now gas has been detected leaking from under driver side seat. After researching the issue on the internet it is clear this is wide spread problem with the possibility of fire and or environmental damage. The car was purchased used one year ago. Nothing has been done yet to correct the problem due to lack of funds to have the dealer address the issue. Most information I have seen place the repair at around $2,000.

- Youngtown, AZ, USA

problem #54

Jul 162010


  • 5,000 miles
2004 Chevrolet Corvette began leaking fuel after 5K miles. Dealer said it was a faulty fuel tank and crossover tube between the two parts of the tank. $1400 to replace fuel tank. The car could have burned to the ground, there was fuel running everywhere at the gas station!

- Huntsville, AL, USA

problem #53

Aug 262010


  • 76,100 miles


04 Corvette ZO6 leaking fuel when I filled it. I have been smelling fuel for a while now and I guess this why. It seems when I was almost done filling it up it started dripping fuel on the ground in front of the L/R tire. Took it to dealer no results yet.

- Fenton, MO, USA

problem #52

Jul 142008


  • 58,000 miles
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.

- Falls Church, VA, USA

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problem #51

Aug 122010

Corvette 8-cyl

  • 29,000 miles
My 2004 Corvette has a problem with fuel leakage when I fill it I get a heavy odor of gasoline im afraid it may burn my house down if I leave it in the garage now.

- Ukiah, CA, USA

problem #50

Jul 112010


  • 21,582 miles


1. traveling in high speed lane of freeway vehicle suddenly stopped running without any forewarning. 2. first and only time this occurred 3. dealer replaced the in tank fuel pump.

- S. Glastonbury, CT, USA

problem #49

Oct 152009


  • 63,000 miles
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.

- Madison, MS, USA

problem #48

Aug 122010


  • 9,450 miles
On Thursday, Aug. 12, 2010, I stopped by at a gas station to fill up my gas tank on my 2004 Chevrolet Corvette coupe. After traveling approximately 4 miles from the gas station, I noticed a gas leak underneath coming from the left driver's side near the gas tank area. After discovering the problem, I immediately drove the car to a Chevrolet service dealership. After having a certified GM mechanic looking at the problem, they discovered is was a defective tank connector (crossover pipe) that cracks under stress. What needed to be replaced was the O-ring seals and connector pipe ($250). The labor charge for replacing these parts on a 2004 Corvette was $845. It is also my understanding that in 2003 to 2004, GM had these crossover pipes changed from a rubber to a steel material because of gas and highway emissions. I would like to make statement to every owner of 2004 Corvette, that there is in fact a defective crossover pipe that will leak gasoline and will eventually cause a fire hazard if it is not replaced.

- Conway, SC, USA

problem #47

Aug 142004

Corvette 8-cyl

  • miles
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

- Tustin, CA, USA

problem #46

Jun 212010


  • 40,600 miles


I bought the 2004 vette coupe on 5-29-10 from a local dealer. The car seemed clean. I have put a little over 1,000 easy miles on the car in 9 weeks. I started to notice a smell coming from the car when I would get home and began to run fans to get it out of the garage. I finally took it to a local Cadillac dealer since I was not sure I could trust the dealer that sold me this car with a problem and they found a gas leak at the joint where the tube that connects the two tanks comes out of the right tank. It only drips when it has been driven but is now quite bad. I have not dared drive it for the last week. It has not been worked on because I was advised to call GM to see if they could help out on this costly repair. I have not heard back from them as yet. The GM rep did ask me to take it back to the original seller for another inspection even though another division of their company has already identified the problem and even showed me the leaking location. This is a very dangerous situation as gas now drips on the ground in front of the right rear tire. Any thing you can do to see to it that this situation is corrected quickly may save someone's life. I consider myself fortunate to have found out what was wrong without being hurt or killed.

- Venice, FL, USA

problem #45

Jul 262010


  • 28,533 miles
Chevrolet Corvette 2004 start noticing a fuel odor in the garage brought to the shop they remove the driver side fuel and discover that it was crack around the crossover pipe.

- Lake Charles, LA, USA

problem #44

Aug 082010


  • 45,830 miles
A 2004 Corvette coup developed a strong gasoline smell and leaks on the driver side when the fuel tank is almost full. Mileage is 45,836. Replaced gas cap to reduce gas smell with no improvement then noticed leak during refueling.

- Marshall, VA, USA

problem #43

Jul 032010


  • 96,000 miles
Each time I fill the gas tank there is a strong gas odor until the fuel level is below half a tank and then the odor of gas is nonexistent. The drivers side of the car has a stronger odor of gas when present.

- Keller, TX, USA

problem #42

Nov 202008


  • 29,331 miles
Left side fuel tank leaking gas.

- Bella Vista, AR, USA

problem #41

Dec 012009

Corvette 8-cyl

  • 45,000 miles
Smell of gasoline when stopped and after car is parked overnight. Updated 08/04/10 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

- Frederick, MD, USA

problem #40

Jun 012010


  • 57,500 miles
Fuel tank is leaking vapors and fuel. 1. there are no specific events leading up to failure 2. failure is continuous 3. nothing has been done to correct. First noticed on or about June 1, 2010.

- Lafayette, LA, USA

problem #39

Jul 162010


  • 40,000 miles
I own a 2004 Chevy Corvette and gasoline and fuel vapors are leaking from my car. One of my two gas tank is the source of the leak and it needs to be replaced. After taking it to gearhart Chevrolet on route 46 in denville NJ, they explained that the entire tank needs to be replace and it will cost over $2,000 for parts and labor. I have noticed that there were many complaints about this issue with the 2004 Corvette and want to know if the issue has cause a recall.

- Hopatcong, NJ, USA

problem #38

Jul 052010


  • 100,000 miles
The contact owns a 2004 Chevrolet Corvette. The contact stated there was an overwhelming odor of gasoline in the vehicle. He replaced the fuel cap but continued to smell the odor. The vehicle was taken for state inspection and did not pass due to a gas leak being found at the rear driver side tire. The vehicle was not repaired. The manufacturer was not contacted. The VIN was not available. The failure and the current mileages were 100,000.

- Chowchilla , CA, USA

problem #37

Jul 052010


  • 100,000 miles
The contact owns a 2004 Chevrolet Corvette. He noticed a gasoline odor after he replaced the gasoline cap, but the odor remained. The vehicle failed the stated inspection, due to a gas leak that was located near the rear left tire. The manufacturer will be contacted. The VIN was not available. The failure and the current mileages were 100,000.

- Chowchilla , CA, USA

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