NHTSA Complaint #11680896 — 2016 CHEVROLET TAHOE

Component Failure: AC condenser assembly failed due to thermal cycling cracks in combination transmission fluid/oil cooler design - exact failure documented in GM TSB 17336-05. TSB states "thermal cycling creates a crack that may allow refrigerant to escape." Safety Risk: AC system failure after sun exposure creates dangerous interior temperatures lasting 30-45 minutes with family including two teenagers in 95°F+ NC summer heat. Risk of heat exhaustion/stroke during highway travel where immediate stopping impossible. Dealer Confirmation: Hendrick Chevrolet diagnosed refrigerant leak from upper left condenser on 7/22/25 (Invoice CTCS913252, $1,904.60). Official work order documents identical symptoms and repair operation covered by GM TSB 17336-05 Special Coverage. Manufacturer Knowledge: GM issued TSB 17336-05 acknowledging their combi-cooler design cannot withstand normal thermal cycling, affecting 908,000+ vehicles. GM provides Customer Service Satisfaction Campaign 17336-01 free repairs for this exact defect but denied my reimbursement (Case #72260590) solely due to mileage, claiming manufacturing design defect becomes customer responsibility after 60k miles. Symptoms: Problem began summer 2024 - AC functions normally when parked in shade but requires 30-45 minutes to cool after direct sun exposure, exactly matching TSB heat-soak failure pattern. No warning lights as system retained sufficient refrigerant until complete thermal stress failure.