NHTSA Complaint #10512154 — 2007 CHEVROLET CORVETTE

JULY 03, 2012 9PM - LOW BEAM HEADLIGHTS FAILED TO TURN ON EITHER AUTOMATICALLY OR MANUALLY BY SWITCH. FOR NEXT SEVERAL DAYS/NIGHTS THE LOW BEAMS WOULD INTERMITTENTLY TURN ON WHEN THE CAR WAS COLD AND TURN OFF AFTER THE CAR WAS WARM. SEARCHING THE INTERNET IDENTIFIED THE UNDERHOOD FUSE BLOCK AS THE MOST LIKELY CAUSE, MANY CORVETTE OWNERS HAD EXPERIENCED THE SAME PROBLEM WITH THE LOW BEAMS AND ISOLATED THEIR PROBLEM TO THIS FUSE BLOCK. I REPLACED MY FUSE BLOCK JULY 15 AND THE PROBLEM WAS FIXED. I DISASSEMBLED THE REMOVED FUSE BLOCK WITH THE INTENT OF REPAIRING IT SO I WOULD HAVE A SPARE FUSE BLOCK IF THE NEW FUSE BLOCK FAILED. AFTER EVALUATING THE DESIGN AND CONSTRUCTION OF THE FUSE BLOCK I CONCLUDED THAT THE FUSE BLOCK WILL HAVE POOR LONG TERM RELIABILITY. I COULD REPAIR THE PROBLEM THAT CAUSED THE LOW BEAM HEADLIGHT FAILURE BUT ANY AND EVERY OTHER CIRCUIT IN THE FUSE BLOCK IS VULNERABLE TO THE SAME FAILURE CAUSE. EVERY COMPONENT/SYSTEM THAT RECEIVES POWER THRU THIS FUSE BLOCK IS VULNERABLE TO EVENTUALLY EXPERIENCING INTERMITTENT POWER PROBLEMS.