Modified material for air intake house

[rojoes]

Many reports premature cracking and deterioration of factory air intake hose. This part is called an Outlet Duct by General Motors and there is a newer one made of different material.

Originally part was made of NBR/PVC - Nitrile Butadiene Rubber/PVC blend. Part # 95489808.

Replacement material is EPDM rubber Ethylene Propylene Diene Monomer Part # 94537633

Insist on the 94537633 part number or you can order it here http://www.ebay.com/itm/New-Air-Cle...ash=item43fdb06950:g:VxgAAOSwUKxYlWSz&vxp=mtr Price is $21.99 with FREE delivery to your door


I decided to make a separate thread since there is so many people affected by this. Perhaps we could even start a petition to get reimbursed from General Motors.

I very much enjoy my Chevrolet Sonic and I bought one because it was a much nicer car than they Toyota Corolla, Honda Fit and Mazda 3 automobiles that I test drove. If something happened and I needed another car today I wouldn’t hesitate to purchase another Chevrolet Sonic.

 

[Papasonic]

My wife's 2012 1.8 LTZ with ~ 41,000 miles, has also been afflicted with this problem. A few days ago she noticed the check engine light came on, and asked me to investigate. I did the usual fluid checks and gas cap check, I didn't even check for codes; I immediately got out my mirror and flashlight, and sure enough, a large split in the outlet tubing.
Being one who likes to repair rather than replace; I used CA glue to repair the split, and after that cured, I used the Flex Seal as seen on TV to completely coat the tubing. After a few coats of this product, and a day to cure; I reinstalled the tube. Amazingly after a few stop/starts, and a few miles, the light extinguished on its own.
I realize this isn't the preferred way to resolve this problem, and will monitor the repair frequently to see if it will be a permanent fix. Who knows, this may outlast the rest of the vehicle.
I can afford to replace the part, but it was the weekend, parts weren't readily available, I had the materials to do the repair, and the wife is upset that her car is broken; besides it was a challenge. What bothers me is if this goes unnoticed, and not corrected, there is the potential for the engine to ingest an appreciable amount of dirt laden, unfiltered air.

 

[2014 Blue RS]

Thanks for the tip. My friend has the 1.8

 

[WyrTwister]

My wife's 2012 1.8 LTZ with ~ 41,000 miles, has also been afflicted with this problem. A few days ago she noticed the check engine light came on, and asked me to investigate. I did the usual fluid checks and gas cap check, I didn't even check for codes; I immediately got out my mirror and flashlight, and sure enough, a large split in the outlet tubing.
Being one who likes to repair rather than replace; I used CA glue to repair the split, and after that cured, I used the Flex Seal as seen on TV to completely coat the tubing. After a few coats of this product, and a day to cure; I reinstalled the tube. Amazingly after a few stop/starts, and a few miles, the light extinguished on its own.
I realize this isn't the preferred way to resolve this problem, and will monitor the repair frequently to see if it will be a permanent fix. Who knows, this may outlast the rest of the vehicle.
I can afford to replace the part, but it was the weekend, parts weren't readily available, I had the materials to do the repair, and the wife is upset that her car is broken; besides it was a challenge. What bothers me is if this goes unnoticed, and not corrected, there is the potential for the engine to ingest an appreciable amount of dirt laden, unfiltered air.

I live in a dusty climate , so that was my first thought when I began reading of this problem .

I agree , GM should make it right , it was / is their error .

God bless
Wyr

 

[Papasonic]

I live in a dusty climate , so that was my first thought when I began reading of this problem .

I agree , GM should make it right , it was / is their error .

God bless
Wyr

GM cost cutting at it's finest!

I know that I was disappointed upon discovering this. If a simple component such as a hose fails at such a premature time/mileage; what other compromises were made on more critical components?

 

[carsNskis]

GM cost cutting at it's finest!

I know that I was disappointed upon discovering this. If a simple component such as a hose fails at such a premature time/mileage; what other compromises were made on more critical components?

Do you bubble wrap every sharp corner in your home too?

Basic economics tells you that if you can make profit by using a more cost effective part then do it. It's a rubber hose, not a transmission so calm your tyts


Sent from my SM-G930V using Tapatalk

 

[Papasonic]

Do you bubble wrap every sharp corner in your home too?

Basic economics tells you that if you can make profit by using a more cost effective part then do it. It's a rubber hose, not a transmission so calm your tyts


Sent from my SM-G930V using Tapatalk

carsNskies,

I was only expressing my perception that manufacturers tend to focus more on cost rather than quality, reliability, or customer satisfaction.

Now that you mention it; there have been quite a few forum member posts regarding manual transmission failures, and replacement.

I didn't get the bubble wrap analogy.

Getting back on topic: Thanks rojoes for sharing information on sourcing the modified material and new part number outlet duct.

 

[carsNskis]

carsNskies,

I was only expressing my perception that manufacturers tend to focus more on cost rather than quality, reliability, or customer satisfaction.

Now that you mention it; there have been quite a few forum member posts regarding manual transmission failures, and replacement.

I didn't get the bubble wrap analogy.

Getting back on topic: Thanks rojoes for sharing information on sourcing the modified material and new part number outlet duct.

Every manufacturer has problems related to cost cutting.... but letting a bad rubber hose shake your confidence in an entire vehicle our brand is like being worried that one day you'll trip and bump your head at something sharp at home so you bubble wrap every corner ;o)

The actual percentage of replaced transmissions to total sold vehicles isn't as significant as this forum presents.

 

[Llia]

Can we replace with silicon(?) aftermarket hoses.

 

[Palmaris]

Being one who likes to repair rather than replace; I used CA glue to repair the split, and after that cured, I used the Flex Seal as seen on TV to completely coat the tubing. After a few coats of this product, and a day to cure; I reinstalled the tube.

Now if that isn't in the next advert for Flex Seal, then I don't know what should be!

 

[carsNskis]

Can we replace with silicon(?) aftermarket hoses.

Rigid tubing is better, as silicone could collapse under vacuum. When you do an intake the couplers are silicone and the piping is rigid.

You could replace the intake tubing with literally anything, it just needs to be able to hold shape under vacuum and flex when the motor does.

 

[SuperFudd]

Just wondering.
When the hose (duct) breaks, do pieces of it get sucked into the engine?

 

[Stew]

Rigid tubing is better, as silicone could collapse under vacuum. When you do an intake the couplers are silicone and the piping is rigid.

You could replace the intake tubing with literally anything, it just needs to be able to hold shape under vacuum and flex when the motor does.

There is only vacuum downstream of the throttle body, not upstream so silicone should be fine. I agree though, doing aluminum tubing with silicone couplers would be best.

You guys should do the 'hard pipe your stock air box' thing and be done with it. The following thread is for the 1.4 but the idea is the same on the 1.8's of course.

http://www.sonicownersforum.com/forum/do-yourself-articles/6385-hard-pipin-your-sab.html

Edit: Ok, technically there may occasionally be a slight vacuum upstream of the TB if your air filter is really dirty, but it would be so slight that it isn't meaningful. Vacuum as most people think of vacuum only exists after the TB since it is the pistons downward movement trying to pull in air against a closed throttle plate that creates the vacuum.

 

[JesusTheAgnostic]

Do you bubble wrap every sharp corner in your home too?

Basic economics tells you that if you can make profit by using a more cost effective part then do it. It's a rubber hose, not a transmission so calm your tyts


Sent from my SM-G930V using Tapatalk

Didn't they cut costs on the transmission too? I've read on here somewhere about some plastic clip instead of a metal one in the transmission or something like that.

 

[carsNskis]

Didn't they cut costs on the transmission too? I've read on here somewhere about some plastic clip instead of a metal one in the transmission or something like that.

I'm sure they cut expenses everywhere possible, but it also appears they rectified the transmission issues and have no problem fixing it.

I'm just saying freaking out about a rubber hose is a little extreme. I drive the piss out of my car constantly (26k a year) and I have no complaints.

I can't speak for everyone about the Sonic but I do know little quibbles with quality are an issue EVERY car has no matter who makes it.

 

[RMinNJ]

I'll take a broken air hose over rusting fenders any time.

 

[$ub$onic]

We may have a replace hose coming out soon that will replace the crap OEM intake tube

Still up in they air with it but there is a chance I will make a batch

 

[TheGreenDragon]

Wonder if you could use the stuff we use in electrical work for creating loose connections to motors in hazardous areas for the intake.

We call it seal-tight. It's metal banded flex hose within a rubber housing. Watertight, rigid, and flexible. Comes in 3/8", 1/2", and 1" sizes.

 

[HookedOnSonics]

We may have a replace hose coming out soon that will replace the crap OEM intake tube

Still up in they air with it but there is a chance I will make a batch

$ub$onic is that picture of a replacement for the factory pipe on a 1.8? You got any ball park ideas on pricing and/or if you'll be making any? Just discovered the issue with mine a couple of weeks ago and am very interested. I used a healthy amount of Gorilla duct tape as a temporary solution but will need a more permanent replacement before too long.

 

[$ub$onic]

That is a picture of what the part would be

Price would be around $120 SHIPPED with clamps


Still seeing if there is any interest before I make a batch