For about 11 years I worked as a tech at a Chevrolet dealership, here are a few that i came across and others that were told about while i was there.
The new car PDI guy told about a rattle from the back of the car. He checked everything under the car couldn't find the cause of the clunk when turning. he finally loaded another guy in the back seat and tried to duplicate the noise. The dude in the back said, "It's coming from this side panel" Tore the panel off and a beer bottle had this note inside, "Finally found it you dumb SOB"
Seen several cases of a screw falling out of the bottom of Q-Jets and going thru the engine.
The old Targetmaster engines were awful. Had instances with crank woodruff keys and valve cover/timing cover bolts left on pistons before the heads were installed. Got so bad toward the end of my time there we were probably warranting 1 out of every 4 sold.
Installed a new 454 in a class A motorhome. Almost made it out the door before a couple rods started knocking. On teardown there wasn't an upper main bearing installed on #4 main. Had to pull that pig all apart again under warranty flat rate.
Had a good customer who bought several trucks a year for his business. His own personal pickup was a loaded Silverado which had a 400 with an oil consumption problem. Back in those days Chevy wouldn't tear an engine down without an oil consumption report. So after GM dicking this guy around, the used truck manager called a wrecker to pick the truck up on S. hiway 79 and then drove it out the door. When the Silverado returned about an hour later, a rod was hanging out the side of the block. Installed a new engine and oil consumption was cured.
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Monty Frerichs
B&M Machine
Box Elder SD
Last edited by RAIV55; 06-08-2013 at 01:13 PM.
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