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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 4 of 4)

« Read the previous 20 complaints

problem #16

Jan 152007


  • 8,400 miles


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.

- Sydney, 00, USA

problem #15

Oct 202009


  • 65,000 miles
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..

- Madison, MS, USA

problem #14

Oct 082008


  • 31,244 miles
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.

- Rockwall, TX, USA

problem #13

Jan 112010


  • miles


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.

- Scottsdale, AZ, USA

problem #12

Nov 012009

Corvette 8-cyl

  • 19,600 miles
Very strong gasoline smell when car is parked in garage. Updated 07/26/10.

- Bend, OR, USA

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problem #11

Dec 012009


  • 53,000 miles
Fuel smell when filling car with gas odor is also in car.

- Tujunga, CA, USA

problem #10

Nov 192009


  • 14,200 miles


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.

- Omaha, TX, USA

problem #9

Nov 082009


  • 10,000 miles
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.

- Sterling, IL, USA

problem #8

Jun 252009


  • 34,000 miles
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.

- Bush, LA, USA

problem #7

Dec 062009


  • 9,642 miles
Gasoline smell/leak when you fill the tank on my 2004 Chevrolet Corvette. There should be a recall as this is a common problem.

- Westborough, MA, USA

problem #6

Jun 152009


  • 34,000 miles


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.

- Miami, FL, USA

problem #5

Jun 012009

Corvette 8-cyl

  • 52,000 miles
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. Updated 003/30/10 updated 10/05/10

- Katy, TX, USA

problem #4

Sep 152009


  • 36,000 miles
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 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!

- Lacombe, LA, USA

problem #3

Feb 012009


  • 5,800 miles
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.

- San Angelo, TX, USA

problem #2

Oct 102008


  • 26,700 miles
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.

- Jacksonville, FL, USA

problem #1

Oct 282008


  • 7,400 miles
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.

- Grant, FL, USA

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