NHTSA Complaint #10790208 — 2009 CHEVROLET SILVERADO

FUEL LEAKING/SPRAYING OUT OF THE REAR AUXILIARY FUEL TANK. I NOTICED A STRONG SMELL OF RAW GASOLINE COMING FROM THE REAR OF THE VEHICLE. UPON FURTHER INSPECTION I OBSERVED THE RAW FUEL WAS COMING OUT OF THE FUEL MODULE CONNECTING FUEL LINE. THE METAL FUEL LINE SITS IN A WELL OF THE REAR TANK AND WAS COMPLETELY COVERED WITH DIRT/MOISTURE/RAW FUEL. THE TANK WAS REMOVED AND WE IMMEDIATELY NOTICED THAT THE METAL PORTION OF THE FUEL MODULE METAL PIPING WAS RUSTED THRU AND THAT WAS WHERE THE RAW FUEL WAS BEING SPRAYED/POOLING IN THE WELL AREA. THE DESIGN OF THE FUEL TANK & MODULE CREATES A PERFECT LOCATION FOR DIRT/MOISTURE TO ACCUMULATE. ANY TYPE OF IGNITION SOURCE COULD HAVE CAUSED A CATASTROPHIC FIRE AND POSSIBLE EXPLOSION. THE REMOVED ORIGINAL FUEL MODULE WAS IN PERFECT WORKING CONDITION EXCEPT FOR THE ROTTED METAL PORTION OF THE MODULE. I REPLACED THE ROTTED FUEL MODULE WITH A NEW GM OEM FUEL MODULE. THIS NEW MODULE HAS THE SAME EXACT CONSTRUCTION AS THE ORIGINAL PART. SINCE THERE IS NO POSSIBLE WAY TO CLEAN OR KEEP CLEAN THE WELL AREA OF THE TANK, I CAN ONLY ASSUME THE NEW OEM PART WILL DETERIORATE IN THE SAME MANNER. THE VEHICLE HAD ABOUT 34000 MILES ON IT WHEN THE CONDITION OCCURRED. SINCE IT IS OUT OF WARRANTY THE NEW MODULE COSTS FOR LABOR AND PARTS WAS IN EXCESS OF $1000.00. IN CONCLUSION I THINK THIS MATTER SHOULD BE INVESTIGATED FURTHER BECAUSE IT IS OBVIOUSLY A SAFETY HAZARD INVOLVING RAW FUEL BEING EJECTED FROM THE FUEL TANK UNDER PRESSURE WHILE THE PUMP IS RUNNING.