NHTSA Complaint #10257966 — 2003 PONTIAC SUNFIRE

THE FRONT WIRING HARNESS ON MY 2003 PONTIAC SUNFIRE 2 DOOR HAS FAILED FOR THE 4TH TIME DUE TO CORROSION OF THE OBVIOUSLY-TOO-SMALL GAUGE WIRING AND INAPPROPRIATE PLACEMENT AND WATER-PROOFING OF THE WIRING HARNESS AND CONNECTORS. HEADLIGHT(S) OR FOGLIGHT(S) TYPICALLY EITHER FAIL OUTRIGHT, OR DIM TO ABOUT 10% INTENSITY, CAUSED BY CORROSION IN THE WIRES AND CONNECTORS. PREVIOUS FAILURES OF THIS WIRING HARNESS AFFECTING BOTH HEADLIGHTS AND/OR FOGLIGHTS OCCURRED IN JAN 2005, JAN 2006, AND JAN 2007, AND WERE REPAIRED BY REMOVAL OF CORRODED WIRE SECTIONS AND RE-SPLICING OF WIRES. DISCUSSIONS WITH BOTH GM AND INDEPENDENT MECHANICS CONFIRM MY SUSPICIONS OF SIMILAR FAILURES IN MANY OTHER SUNFIRES AND CAVALIERS. I AGREE WITH A LIFELONG MECHANIC WHO SAYS THE ONLY PROPER SOLUTION IS A COMPLETE REWIRING JOB. THIS IS AN EXTREME HAZARD AS COMPLETE HEADLIGHT FAILURE OR DIMMING CAN HAPPEN ANY TIME WITHOUT WARNING. A DEAD OF NIGHT FAILURE ANYWHERE, IN THE CITY, NEAR A SCHOOL, OR ON A COUNTRY ROAD AS HAPPENED TO MY DAUGHTER'S FRIEND IN HER SUNFIRE, CANNOT BE CONSTRUED AS ANYTHING OTHER THAN LIFE-THREATENING; FOG LIGHT AND HEADLIGHT FAILURE AT ANY OTHER TIME IS DANGEROUS. IF THE FAILURE OF SUNFIRE/CAVALIER REAR BRAKE AND TURN LIGHTS WARRANTED A 2004 RECALL, THEN SURELY THIS EQUALLY OR MORE THREATENING CHRONIC PROBLEM DESERVES ONE. WHY THIS HAS NOT BEEN ADDRESSED ALREADY IS BEYOND ME. GM HAS ACKNOWLEDGED THE PROBLEM BY ISSUING A SERIES OF TSBS OVER THE YEARS ON THIS PROBLEM: #03018, #0309, #030842002, #021903, AND THE NHTSA HAS BEEN APPRISED OF THEM. I AM A HOBBY MECHANIC WHO HAS SPENT 45 YEARS BUILDING AND RACING POWERBOATS AND WORKING ON AND RESTORING CARS. I KNOW A DESIGN FAULT WHEN I SEE ONE. THIS ISSUE MUST BE ADDRESSED BEFORE SOMEONE IS KILLED OR SERIOUSLY INJURED. THE SUSPECT WIRING HARNESSES SHOULD BE RECALLED AND REPLACED, RATHER THAN WAITING FOR THEM TO FAIL (TIME AND TIME AGAIN) AND THEN MAKING SPLICES TO THE WIRING AND CLEANING UP THE CONNECTORS. *TR