All this crap goes back a looooong way. My first car as a teenager was a '67 Camaro that was hand-me-down from my older brother who got it from my dad. That car had bad motor mounts from the factory. The rubber part of the mounts would break away from the steel part and torque of the motor twisting would pull on the throttle linkage and "floor" the accelerator. GM's fix? They sent the dealers some cables to pass thru the upper and lower motor mounts to tie the two pieces together so the motor couldn't twist when the mounts broke! Unreal.
It still doesn't change the fact that these days, with as complicated as vehicles are, it's got to be pretty damn hard to find some of these problems before production begins. And I'm sure that with as big as these car companies are, with as many layers of bureaucracy as they have, once they find a problem and actually diagnose it and then come up with a solution, the sheer magnitude of the hurdles that have to be jumped to implement a fix must be mind boggling. I imagine that most of the hurdles are in the accounting dept, which ironically, in many cases, is probably the original source of the problem in the first place - trying to save nickles on each and every vehicle by "value engineering" cheaper solutions to everything. If you let the engineers make all the decisions and leave the bean counters out of it, they'd probably never break.... but it would either bankrupt the company or result in $200,000 trucks. Probably both.
I have a friend who used to work as a factory service rep for Mercury Marine. He told me about the introduction of the Optimax line of motors which happened while he was working for them. When they first came out, they got the name Opti-pop because they were blowing up left and right. Turned out the problem was the fuel injection system and the changes that the bean counters made them implement before production. All the testing was done with one injection system and before production began that system was "value-engineered" to save money on the production motors. The problems were eventually fixed and the motors became one of the most reliable and fuel efficient out there but the first couple of years were hell. I have a pair of 250 HP Optimax motors on one of my boats and they've been great and actually get better fuel economy than the equivalent 4 stroke motors.
2002 Chevy 2500HD Crew - Original owner - 408,000 miles so far. All stock with the exception of a lift pump.
Last edited by long-time-dmax; 12-20-2019 at 09:00 AM.