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pretty bad
Typical Repair Cost:
No data
Average Mileage:
60,150 miles
Total Complaints:
2 complaints

Most Common Solutions:

  1. not sure (1 reports)
  2. replace o-rings (1 reports)
2004 Chevrolet Corvette fuel system problems

fuel system problem

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2004 Chevrolet Corvette Owner Comments

problem #2

Apr 012015

Corvette Z06 5.7ls6

  • Manual transmission
  • 58,275 miles


On all 2004 Corvettes there is a good chance that the driver side fuel tank will leak at some point in time. GM had a recall period of 10 years or 100,000 miles. I miss this by four months on the time frame. To take this vehicle in to have this service done to it, cost a total $1300 before taxes and cost of fuel tank. Labor to pull the tank out calls for 10 hours flat rate, and a new fuel tank is $900 including taxes.

So what I did was buy a used fuel tanks for my car. I pulled out the driver side fuel tank out and replace the o-rings in the fuel tank this cost to me because I did the work my self so my cost was $375. I also added Honda-bond with is a fuel resistance silicon adhesive this will stop leak. This will keep the o-rings from leaking again. The people that had the dealership do this job might have the fuel tank leak again down the road because there not any fuel resistance adhesive added to the replacement tank or o-rings .

So what causes this issue? When I pulled my fuel tank the yellow o-ring and green o-ring had flat spots on them, with means when this car had the crossover tube installed into the fuel tank, these two o-rings were pinched and damage, but it took awhile for this issue to show up. I'm the second owner of this car and fuel tank was never pulled out before I got this car. Fuel started leaking from the tank with about 58,275 mile on the vehicle. This happened at the beginning of March 2015 and I fixed this weekend June 20 2015. GM nor NHTSA could not help me get my car fixed so I took personal responsible and fixed my car myself.

I work on cars for a living, but this was the first time I ever pulled a gas tank out of a C5 model Corvette, but I did and most repair car repair shops in the Seattle area will not touch this job with a 10 foot pole. Now it fixed and any Corvette owners that own a 2004 C5 Corvette either in base model convertible or Z06. Will at some point in have this issue creep up so, I just wanted the public to beware of this issue.

- Matt E., Bothell, WA, US

problem #1

May 012009


  • Automatic transmission
  • 62,000 miles

There is a gasoline leak on top of the gas tank in the rear of the driver's side of the car. So far the mechanics working on the car have replaced all of the gaskets for the connections to the gas tank. A total of 4 gaskets have been replaced The gas is still leaking from the same area. They now have to take it all apart again to try to locate the leak.

I would like to know if anyone has had this problem and if so what was done to correct it.

Any information would be appreciated. Thank you

- tricia8018, Toms River, NJ, US

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